Hydraulic drive system with temperature compensation for pressure limit

ABSTRACT

A hydraulic drive system for storing and releasing hydraulic fluid includes a high pressure storage device, a low pressure storage device, and a pump-motor operating at a range of pump-motor speeds for converting between hydraulic energy and mechanical energy. The pump-motor is disposed between the high pressure device and the low pressure device. In normal operation, the hydraulic drive system enters a motoring mode where hydraulic energy is released from the high pressure storage device and converted to mechanical energy using the pump-motor. It also enters a pumping mode where mechanical energy is converted into hydraulic energy. A neutral state exists where hydraulic energy is neither stored nor released from the high pressure storage device. An approach for compensating for temperature changes using varying pressure limits helps to maintain the hydraulic drive system in normal operation, thereby promoting efficiency within the hydraulic drive system.

RELATED CASES

The following cases, entitled Hydraulic Drive System With Neutral DriftCompensation, now issued U.S. Pat. No. 7,673,451, issue date Mar. 9,2010, Hydraulic Drive System With Precharge Logic, now issued U.S. Pat.No. 7,677,037, issue date Mar. 16, 2010, Hydraulic Drive System WithTemperature Compensation For Pressure Limits, now U.S. Ser. No.11/747,034, filed May 10, 2007, Hydraulic Drive System With AggressiveClutching, now U.S. Pat. No. 7,681,392, issued Mar. 23, 2010, andHydraulic Drive System With Exiting from Pumping and Motoring, now Ser.No. 11/747,005, filed May 10, 2007, of which the present case is one,have all been filed on the same date. The contents of the fourapplications that have a different title then the present applicationare hereby incorporated herein in their entirety.

BACKGROUND

Hydraulic drive systems are known to help facilitate the conversionbetween mechanical energy (e.g., in the forming of rotating shafts) andhydraulic energy, typically in the form of pressure. One hydraulic drivesystem that is known for use with respect to vehicles is sometimescalled a hydraulic launch assist. When a vehicle brakes, mechanicalenergy from the vehicle driveline is captured by the hydraulic drivesystem and stored in a high pressure storage device. When the vehicleaccelerates, pressurized fluid in the high pressure storage device isreleased, converting the hydraulic energy into mechanical energy.

Unfortunately, there are various inefficiencies in using a hydraulicdrive system. The inefficiencies include issues related to a pump-motorthat is inaccurately calibrated, changing temperatures affectingpressures within the hydraulic drive system, time required to place thehydraulic drive system into a normal operational state, the time forapplying a clutch to facilitate the conversion between hydraulic energyand mechanical energy, and issues associated with changing states withinthe hydraulic drive system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a vehicle with an exemplaryhydraulic drive system.

FIG. 2 is a schematic illustration of the components of a hydraulicdrive system showing an exemplary flow in both a motoring mode and apumping mode

FIG. 3 illustrates various exemplary inputs and outputs associated withan exemplary hydraulic drive system that are used by a controller.

FIG. 4 illustrates various exemplary logical inputs and outputs into acontroller associated with a hydraulic drive system.

FIG. 5 is an exemplary flow diagram related to an explanation for aswash-plate position command known by the variable SwashCmd.

FIG. 6 is an exemplary flow diagram related to precharge logic

FIG. 7A illustrates a desired change in pressure for a sensor associatedwith an exemplary hydraulic drive system between a motoring mode and apumping mode

FIG. 7B illustrates various graphs of pressure versus volume to showthat as temperature increases, the less volume of hydraulic fluid thatcan be stored at the same pressure.

FIG. 8 illustrates the flow of a heuristic related to temperaturecompensation for pressure limits.

FIG. 9 is an exemplary flow diagram related to compensation for swashneutral drift.

FIG. 10 is an exploded view of a portion of the flow of FIG. 9.

FIG. 11 is an exemplary flow diagram showing the operation of ahydraulic drive system from a neutral state to either one of a pump modeto a motoring and then the exiting from each of the modes back to theneutral state.

FIG. 12 is an exemplary flow of an operation EvalBrakeTorqueAvailassociated with FIG. 11.

FIG. 13 is an exemplary flow of an operation entitledEvalAccelTorqueAvail associated with FIG. 11.

FIG. 14 is an exemplary flow of an operation entitled CheckDisengageCondassociated with FIG. 11.

FIG. 15 is an exemplary flow of an operation entitledCheckDriftCompensationCond associated with FIG. 11.

FIG. 16 is an exemplary flow of an operation entitled CheckDriftExitassociated with FIG. 11.

FIG. 17 is an exploded view of a portion of the flow of FIG. 11 andrelates to a pumping mode.

FIG. 18 is an exemplary flow of an operation entitledCheckBrakeExitConditions associated with FIG. 17.

FIG. 19 is an exemplary flow of an operation entitled BrakeMoreassociated with FIG. 17.

FIG. 20 is an exemplary flow of an operation entitled BrakeLessassociated with FIG. 17.

FIG. 21 is an exemplary flow of an operation entitledCheckBrakeDoneConstRate associated with FIG. 17.

FIG. 22 is an exemplary flow of an operation entitledCheckBrakeDoneVarRate associated with FIG. 17.

FIG. 23 is an exploded view of a portion of the flow of FIG. 11 andrelates to a motoring mode.

FIG. 24 is an exemplary flow of an operation entitled CheckAccelExitCondassociated with FIG. 23.

FIG. 25 is an exemplary flow of an operation entitled AccelMoreassociated with FIG. 23.

FIG. 26 is an exemplary flow of an operation entitled AccelLessassociated with FIG. 23.

FIG. 27 is an exemplary flow of an operation entitledCheckAccelDoneConstRate associated with FIG. 23.

FIG. 28 is an exemplary flow of an operation entitledCheckAccelDoneVarRate associated with FIG. 23.

FIG. 29 is a simplified portion of an exemplary hydraulic circuit for aclutch system for use with an aggressive clutch mechanism.

FIG. 30 is an exemplary flow of a subsystem to a hydraulic drive systemillustrating the concept of aggressive clutching using the hydrauliccircuit of FIG. 29.

FIG. 31 is an exploded view of a portion of the flow of FIG. 30 andrelates to waiting.

FIG. 32 is an exploded view of a portion of the flow of FIG. 30 andrelates to clutch engaging.

FIG. 33 is an exemplary flow of an operation entitledClutchTimeClampingCalc associated with FIG. 32

FIG. 34 is an exploded view of a portion of the flow of FIG. 32.

FIG. 35 is an exemplary flow of an operation entitled ClutchProfileCalcassociated with FIG. 34.

DETAILED DESCRIPTION

Referring now to the discussion that follows and also to the drawings,illustrative approaches to the disclosed systems and methods are shownin detail. Although the drawings represent some possible approaches, thedrawings are not necessarily to scale and certain features may beexaggerated, removed, or partially sectioned to better illustrate andexplain the present invention. Further, the descriptions set forthherein are not intended to be exhaustive or otherwise limit or restrictthe claims to the precise forms and configurations shown in the drawingsand disclosed in the following detailed description.

Further, there are a number of constants introduced in the discussionthat follows. In some cases illustrative values of the constants areprovided. In other cases, no specific values are given. The values ofthe constants will depend on characteristics of the associated hardwareand the interrelationship of such characteristics with one another aswell as environmental conditions and the operational conditionsassociated with the disclosed system.

To facilitate the discussion that follows, the leading digits of anintroduced element number will generally correspond to the figure numberwhere the element is first introduced. For example, vehicle 100 is firstintroduced in FIG. 1.

Overview of an Exemplary Hydraulic Drive System in IllustrativeEnvironment

FIG. 1 schematically illustrates a motor vehicle 100 with an exemplaryhydraulic drive system 102, known by the trademarks Hydraulic LaunchAssist™ or HLA® by the assignee of the present application when usedwith a vehicle 100. A more detailed schematic of hydraulic drive system102 is illustrated in FIG. 2 and discussed in detail below.

Vehicle 100 has four rear drive wheels 104 and two front non-drivewheels 106. In other illustrative embodiments all wheels may be drivewheels. Moreover, there may be more or fewer wheels for vehicle 100.Operably associated with each of the wheels 104 and 106 could be aconventional type of wheel brake 108. Preferably, the wheel brakes 108are part of an overall electro-hydraulic brake (EHB) system, of a knowntype well, and commercially available.

Vehicle 100 includes a vehicle drive system, generally designated 110.Vehicle drive system 110 includes a vehicle engine 112, a transmission114, and hydraulic drive system 102. Transmission 114 is operativelyconnected to engine 112 and transmits the torque generated by the engine112 to wheels 104. Transmission 114 also interacts with hydraulic drivesystem 102 as discussed in greater detail below. The particular type ofengine 112 and transmission 114 and the construction details thereof, aswell as the arrangement of drive system 110 may be varied in a varietyof ways. For example, vehicle 100 is not even limited specifically touse with what is normally thought of as an “engine”, and therefore, itwill be understood that references to an “engine” will mean and includeany type of power source or other prime mover. Finally, although thehydraulic drive system 102 is illustrated and described in connectionwith a vehicle drive system 110, it may be utilized advantageously withany sort of hydraulic drive system of the type illustrated and describedhereinafter, whether or not such system is part of a vehicle.

Extending rearwardly from the transmission 114 and also forming aportion of vehicle drive system 110 is a drive-line, generallydesignated 116. In the illustrated system 100, and by way of exampleonly, the drive-line 116 includes a forward drive shaft 118, anintermediate drive shaft (not visible herein, but illustrated as element202 in FIG. 2), and a rearward drive shaft 120, an inter-wheeldifferential 122 and left and right rear axle shafts 124 and 126. Thoseskilled in the art will understand, from a reading of the presentspecification, that the drive-line 116 has been illustrated anddescribed as including the shafts 118, 202, 120, 124 and 126 primarilyto facilitate understanding of the overall vehicle drive system 110, andnot by way of limitation. For example, there may be fewer or more shaftsand the shafts may be permanently or selectively connected to oneanother by way of clutches.

An exemplary arrangement of hydraulic drive system 102 is illustrated inmore detail in FIG. 2. More specifically, FIG. 2 schematicallyillustrates the exemplary arrangement of the various elements of system102 and their physical relationship with one another. As noted above,the disclosed arrangement is merely to facilitate discussion and thearrangement is not limiting. Moreover, certain elements may be added orremoved without compromising the relevant operation of hydraulic drivesystem 102. FIG. 2 includes a number of sensors, switches, andsolenoids.

Referring now to both FIGS. 1 and 2, in addition to the elements alreadydescribed, which contribute to the flow of mechanical energy, the drivesystem 110 also includes hydraulic drive system 102, as noted above.Hydraulic drive system 102 is directed to the storing and releasing ofhydraulic energy. A clutch 208 within a transfer case 128 helps providethe interface in transferring between mechanical and hydraulic energy asdiscussed in greater detail below.

Schematically in FIGS. 1 and 2, hydraulic drive system 102 includestransfer case 128, a hydrostatic pump-motor 130, an end cover 132retaining a charge pump 204 (shown in FIG. 2) and a plurality of valvemechanisms 222, 232, 242, 246, and 258, a low pressure reservoir 134, afilter assembly 136 and a high pressure accumulator 138. Low pressurereservoir 134 is a type of accumulator, but of the low pressure type asopposed to high pressure accumulator 138. Thus, the terms low pressurereservoir and low pressure accumulator are used interchangeably forelement 134. More generally, accumulator 138 is an example of a highpressure storage device while reservoir 134 is an example of a lowpressure storage device. Since a reservoir is being used, hydraulicdrive system 102 is an example of an open circuit. U.S. Pat. No.6,971,232 illustrates an example of a closed system using an accumulatorrather than a reservoir that is open to atmospheric pressure. Thecontents of U.S. Pat. No. 6,971,232 are incorporated herein by referencein its entirety. For various of the concepts discussed below, either aclosed system or an open system may be used. Thus, general layout ofhydraulic drive system 102 shown in the figures is merely illustrative.

While the various components are illustrated in particular physicalstructures for convenience of discussion it is possible for any or allof the components to be within a single or a subset of structures.Merely by way of example, motor-pump 130 could be incorporated withinend cover 132, or these two components and transfer case 128 could belocated within a single structure as illustrated schematically inFIG. 1. Moreover, not all components or sub-components (e.g., a specificelement) are required. For instance, while a charge pump 204 isillustrated, in practice such a pump may not be required in view of thedual operationality of pump-motor 130 as discussed below. For example, acharge pump may not be required if a low pressure closed accumulatorwere used rather than a low pressure reservoir 134 at atmosphericpressure.

In general terms, the pump-motor 130 and components within end cover 132provide the hydraulic pathway for movement of a hydraulic fluid such asoil between low pressure reservoir 134 and high pressure accumulator138. As illustrated using a combination of FIGS. 1 and 2, transfer case128 includes a shaft 206 that is mechanically connected to both thepump-motor 130 and the charge pump 204. A clutch 208 and gearing 210selectively transfers torque between shafts 202 and 206.

The pump-motor 130 is used to convert between mechanical energyassociated with the various shafts, including shafts 206, and hydraulicenergy as stored in the form of pressure within hydraulic drive system102. In normal operation of drive system 102 in a pumping mode,mechanical energy is stored as hydraulic energy while in a motoringmode, hydraulic energy is transferred to mechanical energy. In aprecharge mode as discussed below with respect to FIG. 6, mechanicalenergy is also converted to hydraulic energy using pump-motor 130.

Typically, drive system 110, including hydraulic drive system 102,operates in two different modes at different times. In a first mode ofdrive system 110, called a regeneration or pumping mode (typicallyoccurring in a deceleration cycle), a vehicle slows down, such as by anoperating signal a braking operation. Kinetic energy of the vehicle thendrives the pump-motor 130 as a pump, transferring hydraulic fluid fromthe low pressure reservoir 134 to the high pressure accumulator 138, andremoving additional torque from drive-line 116. While not necessarilyrequired, one advantage of using charge pump 204 is that it helps toprevent undesirable cavitation within pump-motor 130. In the illustratedsystem 100 energy comes from wheels 104 in the form of torque, throughaxle shafts 124 and 126, through differential 122, and then by way ofshafts 116 and 202 into transfer case 128. In some approaches, wheels106 may include appropriate shafting and related mechanisms to permit asimilar recovery of kinetic energy. When clutch 208 is applied, energyof braking is transferred through gearing 210 to shaft 206, and finallyto charge pump 204 and pump-motor 130. When a nitrogen gas accumulatoris used, the fluid compresses the nitrogen gas within the accumulator138 and pressurizes hydraulic drive system 102. Under some circumstancesit may be possible to undertake a regeneration of pumping mode usingengine 112 by way of transmission 114 and shaft 118, also connected tointermediate shaft 202.

In a second mode of drive system 110, called a launch assist or motoringmode (typically occurring in an acceleration cycle), fluid in the highpressure accumulator 138 is metered out to drive the pump-motor 130 as amotor. Pump-motor 130 applies torque to shaft 206 that is transferredthrough gearing 210, through applied clutch 208 and then through shafts206, 120, differential 122, axle shafts 124 and 126, and finally towheels 104. The motoring mode stops when most of the pressure isreleased from high pressure accumulator 138, as discussed in more detailbelow. Before motoring can again commence, regeneration of the highpressure accumulator 138 using the pumping mode must occur.

A controller 140 at least partly controls hydraulic drive system 102.Various informational inputs are received by controller 140, and thenheuristics, i.e., logical rules or processes, are applied to the inputs.Outputs are then generated that influence operation of the hydraulicdrive system 102 in the context of overall operation of drive system 110of vehicle 100. While a separate controller 140 is illustrated,controller 140 may be incorporated into an overall vehicle electroniccontrol unit (ECU) or as part of an ECU associated with engine 110 ortransmission 114 or some combination thereof.

Various inputs and outputs associated with hydraulic drive system 102that are used by controller 140 are illustrated in FIG. 3. For each ofthe sensors or switches discussed in FIG. 2, the same switch or sensoris shown in FIG. 3. Similarly, for each of the solenoids discussed inFIG. 2, a corresponding output from controller 140 is also shown in FIG.3. As illustrated in FIG. 3, some of the inputs received by controller140 from the elements associated with FIG. 2 are analog, while othersare either digital or time-related. Similarly, some outputs to elementsassociated with FIG. 2 have a range of values or are proportional innature while others are binary in nature.

Further, as illustrated in FIG. 3, when a separate electronic controlunit (ECU) is in communication with other ECUs within vehicle 100,controller 140 receives message inputs from the overall vehicleController Area Network (CAN) and submits message outputs to the CAN. Awell known communications standard defined by the Society of AutomotiveEngineers (SAE) is SAE J1939 for CAN-based communications. SAE J1587 isanother possible communications standard that could also be used, but isgenerally not as robust. Moreover, other communications standards, suchas ISO9141 K, or other known standards, may be used. The terminologyassociated with the various inputs, which follows, is provided inaccordance with J1939 in accordance with the specifications for thatstandard and is.

Examples of possible CAN messages that can be input into controller 140follow in Table 1:

TABLE 1 Can Message Inputs Driver's demand, engine - percent torqueDriver's demand, engine - engine speed Wheel-based vehicle speed Inputshaft speed Output shaft speed (TransShaftSpeed) Actual gear ratioCurrent gear Accelerator pedal position ABS active Nominal friction -percent torque

Examples of possible CAN messages that can be output from controller 140follow in Table 2:

TABLE 2 Can Message Outputs Override control modes Requested torqueRequested speed

Referring back to FIG. 2, filter assembly 136 includes valving,including a filter manifold 212, a valve mechanism 213 and a digitalswitch 214 that triggers only when the filter is full. Switch 214 offilter assembly 136 is also illustrated in FIG. 3 as one of the digitalinputs into controller 140. It is envisioned that various filterassemblies 136 may be used within hydraulic drive system 102. Oneexemplary assembly 136 is discussed in co-pending application Ser. No.11/408,504, which is a continuation-in-part of application Ser. No.10/828,590 and a continuation-in-part of Ser. No. 10/624,805, all ofwhich are incorporated herein in their entirety.

Filter assembly 136 is in communication with a port of the low pressurereservoir 134 by means of a conduit 215, disposed on the “low pressure”side of the hydraulic drive system 102. In general, the conduitsassociated with the “low pressure” side are illustrated by closelydashed lines between components while conduits associated with the “highpressure” side are illustrated by solid lines between components.Internal conduits disposed solely between elements making up a componentare illustrated in a “bolder” line weight and are not necessarily partof the “high pressure” or the “low pressure” side of the system. Often,they are selectively part of one side or the other.

The operation and operation of an exemplary filter assembly 136 in thecontext of a hydraulic drive system such as exemplary hydraulic drivesystem 102 is discussed in greater detail in U.S. Pat. No. 6,971,232,the contents of which are incorporated herein by reference in theirentirety.

In one illustration pump-motor 130 is of the variable displacement type.However, the pump-motor 130 may be of many types of constructionsincluding, but not limited to bent axis, vane, or radial piston. In thepresent illustration pump-motor 130 is an axial piston type. It includesa swash-plate 216 contained within a pump-motor unit 217 and two swashposition sensors 218 and 220. To vary the angular displacement ofswash-plate pump-motor unit 117 includes some sort ofdisplacement-varying means, such as at least two fluid pressure servoactuators (stroking cylinders) of the type shown in FIG. 2 anddesignated as 221. More information concerning the stroking cylinders isprovided in U.S. Pat. No. 7,076,946, which is incorporated herein in itsentirety. Any of a variety of servo actuators may be used and are notlimited to the type of actuators schematically represented in FIG. 2.The servo actuators 221 are connected hydraulically to the outlets of atypical electro-hydraulic controller by way of conduits 219, theelectro-hydraulic controller labeled as a swash control valve 222. Swashcontrol valve 222 is located within end cover 232. The operation of theswash control valve 222 is to communicate pressurized fluid from aconduit 225 on the “high pressure” side of the system to the servoactuators 221 using conduits 219 as appropriate to achieve the desiredangle and displacement of swash-plate 216, all of which is generallywell known to those skilled in the pump and motor art, and especially,in the axial piston pump art. To control the operation of theappropriate servo actuators 221, swash control valve 222 includes amotor solenoid 224 and a pump solenoid 226. The two solenoids arecontrolled proportionally by controller 140 and are used to positionswash-plate 216, by way of valve 222 and the appropriate servo actuator221, either in a positive angular displacement when the motoring mode isdesired or in a negative angular displacement when the pumping mode isdesired. The angular displacement of swash-plate 216 is determined byeither position sensor 218 or position sensor 220, the readings of whichare then input into controller 140, as shown in FIG. 3. Typically, onlyone sensor is required, the other sensor acting as a backup in case offailure of the other sensor. It is possible however, that both sensors218 and 220 might be used together to provide an average determinationof the angular displacement of swash-plate 216.

Whenever the pump-motor unit 217 is in its neutral condition (which isthe typically the case whenever the vehicle is neither in motoring modenor in pumping mode), there is substantially no flow within thehydraulic drive system 102 between the pump-motor 130 and theaccumulators 134 and 138. However, as is well known, because of thepre-charge on each of the accumulators 39 and 41, as will be discussedin greater detail subsequently, the hydraulic drive system 102 remains“pressurized” even while the pump-motor unit 217 is in its neutralcondition. When pump-motor unit 217 is in its neutral condition, thenideally swash-plate 216 has zero angular displacement. In actuality,inefficiencies result because of the swash-plate 216 drifting away fromits zero angular displacement or alternatively, while the swash-plate216 is in its correct orientation there is an issue with the signal fromsensor 218 and/or 220 that drifts. Thus, it is desirable to addressdrifting related to measurements or the actual positioning ofswash-plate 216. A mechanism to reduce drift is addressed below.

In addition to swash control valve 222, end cover 132 includes a modecontrol valve assembly 230. In turn, mode control valve assembly 230includes a mode valve 232. Operably associated with, i.e., incorporatedinto, the mode control valve 232 is a step-orifice control valve 234,and a solenoid type mode pilot valve 236 with an on/off solenoid 238,the outlet of the mode pilot valve being in communication with a sourceof low pressure (such as reservoir 134, or merely the low pressure sideof the hydraulic drive system 1023) by means of a conduit 240. Theoperation and operation of an exemplary mode valve assembly 230 in thecontext of a hydraulic drive system such as exemplary hydraulic drivesystem 102 is discussed in greater detail in U.S. Pat. No. 6,971,232,the contents of which are incorporated herein by reference in theirentirety.

End cover 132 also includes an isolation valve 242 that is disposed inseries in conduit 243 between high pressure accumulator 138 and swashcontrol valve 222. Isolation valve 242 is preferably a poppet-typevalve, which is solenoid and is operated by solenoid 244. Wheneverhydraulic drive system 102 is operating, the isolation valve 242 is“ON”, i.e., high pressure is freely communicated from the high pressureaccumulator 138 to the swash control valve 222 by way of conduit 223.Whenever the hydraulic drive system 11 is “OFF”, the isolation valve 61is spring-biased to the position shown in FIG. 2, in which the isolationvalve keeps the pump-motor 130 and the swash control valve 222“isolated” hydraulically from the high pressure accumulator 138, so thatthe high pressure accumulator 138 does not “leak down” through the swashcontrol valve while the system 102 is not operating. The isolation valve242 acts as a “key on” for the hydraulic drive system 102. It is used toput the hydraulic drive system 102 in standby. It isolates the highpressure side of the hydraulic drive system 102 from the low pressureside of the system. It also provides pilot pressure to the by-pass valve246.

References herein to the hydraulic drive system 102 being “OFF” will beunderstood to mean and include both that portion of the vehicle 100operating cycle when the vehicle 100 is not in a pumping-motoring mode,as well as those times when the vehicle 100 is not operating at all(engine “off” condition).

End cover 132 also has a by-pass valve 246, which may also be referredto as an “unloading” valve or as a “dump” valve, as those terms are wellunderstood in the valve art. Bypass valve 246 is disposed between theoutlet port A of the pump-motor unit 217 at its input and the “lowpressure” side of the hydraulic drive system at its output. It is usedto “unload” the pump-motor 130.

To help determine the pressure level within the “high pressure” side,such as within conduit 248, end cover 132 includes a sensor 249, thereadings of which are input into controller 140 as shown in FIG. 3.Sensor 249 may be of any type and is not limited to an analog sensor.Sensor 249 is used to measure exit pressure from port A of pump-motor130.

The by-pass valve 246 will “unload” the pump-motor 130 whenever theengine is “off,” i.e., no driving pressure is present in the conduit 223or in conduit 248, so that the pump-motor 130 does not transmitunintended torque to the shaft 202. To unload the pump-motor 130, aby-pass pilot 250 with associated controllable solenoid 252 isoperatively connected to the by-pass valve 246 by an internal conduit256. The by-pass pilot 250 selectively permits the by-pass valve 246 toopen, thereby releasing pressure from the “high pressure” side of thesystem to the “low pressure” side. When hydraulic drive system 102 isoperational, however, the by-pass pilot 250 and associated solenoid 252prohibit the pressurized fluid from passing through the by-pass valve246, as is well known.

The hydraulic drive system 102 also includes, in the end cover 132, arelief valve generally designated 258 which, as is shown in FIG. 2, isspring biased to a closed position. The valve 258 is illustrated as apoppet valve. An inlet of the relief valve 258 is in communication witha conduit 260, which interconnects the inlet of the relief valve 258with the port of the high pressure accumulator 138 by way of conduit223, and with the inlet of the mode control valve 230. Whenever thepressure in the conduit 260 exceeds a predetermined maximum, the reliefvalve 258 is biased (moved “left” in FIG. 2) to a position which permitscommunication from the conduit 256 to a conduit 261, which is on the“low pressure” side of the hydraulic drive system 102.

A charge by-pass valve assembly 262, including a charge by-pass valve263, a charge by-pass pilot 264, and a charge by-pass pilot solenoid 266are illustrated in FIG. 2 as disposed between low pressure conduit 270and low pressure conduit 215. Charge by-pass valve assembly 262 isclosed by way of solenoid 266 during a pumping operation so that fluidflowing through charge pump 204 and pump-motor 130 is not simplyrecycled back to low pressure reservoir 134 without charging highpressure accumulator 138. However, the charge by-pass valve assembly 262is open during motoring as illustrated in FIG. 2 and discussed ingreater detail below.

The high pressure accumulator 138 is illustrated as being locatedoutside of end cover 132. However, as noted above, in some casescomponents such as the high pressure accumulator 138 can be located inthe same physical housing or structure as those discussed with respectto end cover 132. Similarly, components physically located within endcover 132, for example, may be associated with other structures withoutprecluding proper operation of hydraulic drive system 102.

High pressure accumulator 138 represents the termination of the “highpressure” side of hydraulic drive system 102 in association with conduit223. High pressure accumulator 138 includes a high pressure accumulatorunit 280, a pressure level sensor 282 and a high pressure accumulatorproximity switch 284. Sensor 282 is analog and is used to measure thepressure associated with or stored in the accumulator unit 280. By wayof example only, the high pressure accumulator 138 is of the gas-chargetype. At the end of a typical deceleration cycle (pumping mode), thehigh pressure accumulator unit 280 is charged up to the maximum systempressure, typically about 5000 pounds per square inch (PSI), butpossibly even higher.

During a motoring mode where the stored pressurized fluid withinaccumulator 138 is released, a pressure point may be reached where highpressure proximity switch 284 generates a digital signal indicating theclosing of the accumulator unit 280, whereby further flow of pressurizedfluid from the accumulator is prohibited. Switch 284 also selectivelyprovides that signal as an input to controller 140 as shown in FIG. 3.The rules governing activation of high pressure accumulator proximityswitch 284 are discussed in greater detail below. However, in general,switch 284 only triggers when too much of the pressurized fluid hasescaped from accumulator unit 280 during the motoring mode and thepressure within the accumulator unit has abruptly dropped toward zero.This condition is undesired. Nor does it occur frequently. However, whenit does occur, hydraulic drive system 102 uses the occurrence to learnhow to prevent it as discussed below with respect to the temperaturecompensation for pressure limits. A hydraulic pressure is necessarilymaintained, within the accumulator 138, such that a minimum amount ofoil is always retained in the high pressure accumulator and such thatthere is always a predetermined, minimum charge pressure within both ofthe conduits 223 and 260.

It is important to be able to stop motoring before switch 284 isactivated. However, the amount of fluid that can be ejected from thehigh pressure accumulator unit 280 varies with temperature. It is verydifficult to accurately measure a temperature in real-time or nearreal-time within hydraulic drive system 102 in association with theoperation of high pressure accumulator 138. Thus, a different approach,based on a pressure compensation, is disclosed below to accuratelycontrol the flow from the accumulator 238 and to stop it before theactivation of switch 284. Nevertheless, if the pressure withinaccumulator 138 and associated conduits 223 and 260 does drop towardzero, resulting in activation of switch 284 to close accumulator unit280 from additional outward flow then two things occur: first, thecondition is used to adjust the pressure threshold such that such anexcessive flow is prevented in the future as discussed with respect totemperature compensation for pressure limits, below; and second, aprecharge operation such as discussed below is required.

Low pressure accumulator or reservoir 134 represents the termination ofthe “low pressure” side of hydraulic drive system 102 in associationwith conduits 215 and 268. As discussed in more detail below, conduit215 is used to provide hydraulic fluid to low pressure reservoir 134 byway of filter assembly 136 while conduit 268 represents the pathway bywhich fluid is removed from the reservoir such as that necessary tocharge high pressure accumulator 138.

When element 134 is a reservoir, as shown in the exemplary system 102,it includes a hydraulic fluid level sensor 286 and a hydraulic fluidtemperature sensor 288. The sensors may be analog or digital or of anytype performing the requested function. In general, the type of sensorsused within hydraulic drive system 102 is not intended to be limited tothat illustrated. The level of fluid within reservoir 134 increases asmotoring takes place and decreases as pumping removes fluid from thereservoir to recharge high pressure accumulator 138. The fluid level isalso increased when hydraulic drive system 102 is shut down. Typically,the temperature of the hydraulic sensor will increase as hydraulic drivesystem 102 is utilized, but is also influenced by outside environmentalconditions such as ambient temperature.

Transfer case 128 and several of its elements were discussed above withrespect to FIG. 1. Transfer case 128 represents the interface betweenthe mechanical portions of the vehicle drive system 110 and hydraulicdrive system 102. Intermediate shaft 202 forms a portion of the vehicledrive-line 116. Shaft 202 is selectively engaged to hydraulic drivesystem 102 by way of a clutch 208. In the illustrated system, clutch 208is pneumatically operated by way of a clutch solenoid 290 forming partof a clutch valve 292, the activation signal of which is generated bycontroller 140 as shown in FIG. 3. When aggressive clutching of the typediscussed below is utilized within hydraulic drive system 102, thensolenoid 290 is preferably based on pulse width modulation (PWM) so thatit can be selectively and gradually applied. Otherwise, a simpler on/offsolenoid controls a mechanical, dog-type clutch. A correspondingConfirmation that the clutch has engaged is determined using digitalclutch sensor 294, which is input into controller 140 as a transfer casestatus switch digital signal. Gearing 210 is shown using a two-stagereduction so as to provide an appropriate balance between the rotationalspeed and associated torque of shaft 206, which is connected topump-motor unit 217 and charge pump 204. Other gear ratios may also beused depending on the arrangement desired and the nature of the pumps.Shaft 206 selectively rotates. It will not always be rotating even ifshaft 202 is rotating. On the other hand, it is possible for shaft 206to rotate even if shaft 202 is not rotating. Clutch 208 and gearing 210provide the interface between shafts 202 and 206.

To determine the speed of shaft 206, a speed sensor 296 is used. Thespeed of shaft 206 is then input as a timer input into controller 140,as shown in FIG. 3. Typically, the speed of shaft 206 is measured inrevolutions per minute although other units of measurement may also beused. Speed sensor 296 provides another mechanism to determine if clutch208 has engaged, even if clutch sensor 294 suggests that the clutch hasengaged. Associated with clutch 208 is a clutch solenoid 290, which isselectively activated by controller 140, as shown in FIG. 3.

Still referring to FIG. 2, the pump-motor unit 217 includes a port(designated “A”), which is connected by means of the “high pressure”level conduit 248 to the mode control valve 232. The pump-motor unit 217also includes another port (designated “B”) which, by means of the “lowpressure” conduit 270, is in fluid communication with the filterassembly 136 after passing through the charge by-pass pilot 264 andcharge by-pass valve 262, and into “low pressure” conduit 217.

Generally, as shown by the appropriate arrowed lines associated with thefluid flow in FIG. 2 for “pumping” and “motoring”, when the pump-motorunit 217 is in the pumping mode, the port A is the pressurized, outletport (see arrows in pump symbol in FIG. 2), and when the unit is in themotoring mode, the port A is the pressurized, inlet port and the port Bis the exhaust, outlet port.

At this point, to provide background for the discussions of particularaspects of hydraulic drive system 102 that follow, the general operationof the hydraulic drive system during routine motoring and pumping willbe summarized with respect to FIG. 2. The discussion that followsassumes that accumulator 138 is already charged beyond a certain minimumthreshold pressure since a typical pumping operation is illustratedfirst. The ability to efficiently precharge hydraulic system 102 duringwhat would typically be a motoring operation if accumulator 138 is lessthan a minimum threshold pressure is discussed below.

As mentioned previously, when the vehicle 100 is neither deceleratingnor accelerating, the pump-motor unit 217 and charge pump 104 arede-clutched, by the mechanism of a clutch 208. With the pump-motor unit217 and charge pump 204 de-clutched from the intermediate drive shaft202, the overall vehicle drive system 110 shown in FIG. 1 operates inthe same manner as if the hydraulic drive system 102 were not present.

When the vehicle operator begins to perform a braking operation which isrepresented in FIG. 3 with respect to the illustration of the vehiclebrakes 302 and a corresponding brake sensor 304 showing the degree ofrequested braking in an analog format, one result is that the clutch 208is actuated using clutch valve 292 by way of solenoid 290, such that thepump-motor unit 217 is now clutched to the drive-line system 116 (i.e.,to the intermediate drive shaft 202). As discussed below, it has beendetermined that there are undesirable inefficiencies in applying theclutch in a traditional manner. To reduce those inefficiencies, in oneexemplary approach hydraulic system 102 implements what may sometimes bereferred to as aggressive clutching.

Once clutch 208 is applied, an appropriate command signal is provided bycontroller 140 to pumping solenoid 226 of swash control valve 222,displacing the swash-plate 216 in a “negative” direction such that therotation of the intermediate drive-line 202 (with the vehicle moving ina forward direction) causes the pump-motor unit 217 and the charge pump204 to pump pressurized fluid from the port A to the conduit 248. Thefluid is pulled from low pressure reservoir 134 by way of conduit 268and first passes through charge pump 204 before reaching port B of thepump-motor 217 by way of “low pressure” conduit 270, where it enters thepump motor unit.

The displacement of the swash-plate 216 (and therefore, the fluid outputper rotation of the drive-line 202) is typically proportional to theextent to which the vehicle operator depresses the brake pedal. It isknown how to set the displacement of the swash-plate 216 proportional tothe brake torque applied by the operator, or to the displacement of thebrake pedal, and therefore further discussion of the displacement of theswash-plate 216 is not necessary herein.

With the charge pump 204 and pump-motor unit 217 in the pumping mode,pressurized fluid communicated through the conduit 248 unseats a poppetmember in the mode control valve 232, such that the pressurized fluidflows into the conduit 223, and thereby pressurizes the high pressureaccumulator 138. At the same time, conduit 260 is also charged with thepressurized fluid, but the fluid flow does not take place along thisconduit.

At the completion of the deceleration portion of the braking cycle(pumping mode), the vehicle operator may release the brake pedal 302 andsubsequently begin to depress the accelerator. This event is representedas one of the possible CAN message inputs to controller 140 discussedabove with respect to FIG. 3. Controller 140 communicates an appropriatesignal to swash control valve 222 by way motoring solenoid 224, whichuses pressure to command the pump-motor unit 217 to transition from thepumping mode (described previously), to the motoring mode.

In the motoring mode, the swash-plate 216 is disposed at an angularinclination opposite that which existed when the unit was in the pumpingmode (i.e., the swash-plate 216 goes “over-center” to a positive angularinclination). When the pump-motor unit 217 is in the motoring mode, theswash-plate 216 is displaced such that flow through the pump-motor unit217 (from port A to port B) will cause the pump-motor unit to transmittorque to the drive-line shaft 202, tending to drive the intermediateshaft 202 of the drive-line system 110 in a direction corresponding tothe same forward movement in which the vehicle is already engaged. Byway of example only, the swash control valve 222 is constructed suchthat pressurized fluid can always flow from the conduit 248 to theconduit 223 (i.e., the pumping mode). However, only when the mode pilotvalve 236 receives an appropriate input signal to its solenoid is therean appropriate pilot signal to solenoid 238. The pilot signal assists inthe opening of the poppet member of mode valve 232 to permit relativelyunrestricted flow of high pressure fluid from the accumulator 138through the conduit 223, and then through the conduit 223 to the port A(inlet port in motoring mode) of the pump-motor unit 217.

Energy stored within the high pressure fluid is transferred throughpump-motor unit 217 to rotating shaft 206. The energy is transferredmechanically through gearing 210 and to intermediate shaft 202 whenclutch 208 is applied. The energy is then transferred along drive-linesystem 110 to wheels 104.

The “low pressure” fluid exits pump-motor unit at port B into conduit270. It then passes through charge by-pass valve assembly 262, which hasbeen opened as opposed to its state during pumping and into conduit 215where it then goes through filter assembly 136 and into low pressurereservoir 134.

Logical Inputs and Outputs into the HLA Controller

An overview of the control logic associated with controller 140 isillustrated in FIG. 4, which illustrates at least a subset of thevarious inputs that may be provided to controller 140. Some of theinputs into the control logic of FIG. 4 are constants while others arevariables. Rules implemented in controller 140, as discussed in greaterdetail below, result in the various outputs to elements illustrated inFIG. 2 by way of the specific inputs illustrated in FIG. 4. An overviewof the various inputs identified in FIG. 4 is provided in Table 3, whichfollows. A number of the inputs are discussed in greater detail belowwith respect to specific operations associated with hydraulic drivesystem 102.

TABLE 3 Input Comments SwashCmd This input results from a determinationof a swash-plate position command, discussed below with respect toEquations 1, 2, and 3 in combination with FIG 5. SwashFbk Sensor readingfrom sensor 218 and/or sensor 220. AccPress Sensor reading from sensor282. AccState Signal from the high pressure accumulator proximity switch284. The two states associated with the switch are “accumulator notempty” (ACC_NOT_EMPTY) and “accumulator empty” (ACC_EMPTY). Duringnormal operation of hydraulic drive system 102 moving between motoringand pumping the switch should not change states into (ACC_EMPTY) unlessthe accumulator is undesirably bled below a threshold minimum pressure,meaning that more volume of hydraulic fluid has been removed from theaccumulator unit 280 then desired at a particular temperature, asdiscussed with respect to FIGS. 7 and 8 below. ReservoirLevel Sensorreading from level sensor 296. TCaseState Signal input from t. casestatus switch (clutch sensor) 294. OutputShaftSpeed Input from the CANrepresenting the speed of shafts 124 and 126 to wheels 104. The shafts124 and 126 selectively rotate depending on the application ofmechanical energy within vehicle 100 and in drive-line 116. HLAOpModeThis input is an internal variable. The controller 140 monitors a numberof CAN signals and (gear, engine speed, ABS status, Cruise status, theHLA -On/Off switch) and tells the hydraulic drive system 102 whether ornot it may operate. For example, if the system is in a normaloperational mode then a flag “vsc_normal” is set. If the hydraulic drivesystem 102 is to shut down, there are two different ways for it to shutdown. A so- called expedited “hard shutdown” takes place in atime-critical situation such as when the anti- lock brake systemactivates and the hydraulic drive system is to be overridden or whenthere is a loss of control of the hydraulic drive system 102. Aso-called “soft shutdown” indicated by an input value of“VC_SOFT_SHUTDOWN” takes place when a cycle is first completed and thenthe system shuts down (e.g., a predefined temperature limit isexceeded). A vehicle operator is more likely to notice a “hard shutdown”then a “soft shutdown”. Ignition This input tells controller 140 whetherengine 112 is on or off. When the ignition is turned off, the pressurefrom the high pressure 238 is typically bled off, necessitating aprecharge mode when the hydraulic drive system is reactivated asdiscussed below. PumpSpeed Relates to the speed of pump-motor unit 217and is a measurement provided by sensor 296. SwashAccelLimit This inputrepresents the maximum angular displacement that is permitted based onconditions affecting hydraulic drive system 102 (e.g., accumulatorpressure 282, high pressure proximity accumulator state 284 and faultsdetected) and the speed of pump-motor 217 during motoring mode. If thespeed is greater than a desired threshold (e.g., greater than 2000revolutions per minute (RPM)), the maximum angular displacement istypically decreased from the maximum permitted for the particular swashpump-motor 217 to minimize the possibility of damage to the pump-motorunit. Normally, the pump has a displacement that ranges between +/−fifteen (15) degrees. For motoring, the convention used in the presentapplication is that it has a positive angular displacement. The specificSwashAccelLimit is directly derived from the mechanical operation of thepump-motor 217 and is typically associated with a lookup table. See FIG.13 and FIG. 23. SwashBrakeLimit This input represents the maximumangular displacement that is permitted based on conditions affectinghydraulic drive system 102 (e.g., accumulator pressure 282, highpressure proximity accumulator state associated with switch 284 andfaults detected) and the speed of pump-motor 217 during pumping mode. Itis measured based on a negative angular displacement using theconvention of the present application. The discussion with respect toSwashAccelLimit is applicable here. See FIGS. 12 and 17. FaultLevel Thisinput represents a fault from a fault management routine. Some faultsare hardware related (e.g., a failure of one of the sensors, solenoidsor a hardware fault communicated by the CAN). Other faults relate tologic issues from system operationality where an expected output (e.g.,movement of swash-plate 216) does not follow from a command to move theswash-plate. In one exemplary approach, one type of fault level may bedesignated as fault level “1” while a different type of fault level maybe designated as fault level “2”. If there are no faults then thevariable FaultLevel is set to “0” (neither “1” nor “2”). A fault willalso result under other conditions, such as too little hydraulic fluidin system 102 as determined by level sensor 286 within low pressurereservoir 134. FaultId An input giving the fault identification.ModeClosed An input that is based on a determination that mode valve 232is closed. AccPressMax This is an input into controller 140 coming froma table taking into account the temperature. At different temperaturesthis number is different. At this pressure the pumping mode is exited.In one exemplary approach the maximum pressure is 5000 PSI. An exemplarygraph showing how the input may be provided in Bars at varioustemperatures in degrees Celsius follows:

MaxAccPresstoBrake This is an input into controller 140 coming from atable that takes into account the temperature. At different temperaturesthis number is different. It is the maximum pressure at which thehydraulic drive system 102 can still enter into pumping mode. This isalso the pressure at which, if the system is in a pumping mode, it willenter the exit state. In one exemplary approach, it uses the same graphas for AccPressMax, but the pressures are offset by a negative 25 Bars.Thus, for example, the values at the transition points would be: 270-25,345-25 and 345-25. MinAccPressToAccel MinAccPressToMotor This isactually an internal variable related to the temperature compensationheuristic discussed below with respect to FIGS. 7_and 8_. It is theminimum pressure at which the hydraulic drive system 102 can still enterinto motoring mode. It is also the pressure at which, if the system isin motoring mode, it will enter into an exit state. Typically thisvariable is set equal to the value of AccPressMin plus an offset.OilTemp The temperature measured by sensor 288 in reservoir 134.

Table 4 provides an overview of the various outputs of controller 140identified in FIG. 4. A number of the outputs are discussed in greaterdetail below with respect to specific operations associated withhydraulic drive system 102.

TABLE 4 Output Comments MPRDKeepAlive An output from controller 140 tothe main power relay driver circuit (MPRD) of vehicle 100. When theignition of vehicle 100 is turned off controller maintains this signalhigh (MPRDKeepAlive) to indicate to the MPRD circuit that it must notyet turn off the power on the actuators associated with the system untila controlled shutdown of hydraulic drive system 102 takes place. Amongother things, accumulator 138 is bled, and controller 140 also ensuresthat the various valves are turned off in a particular sequence,beginning first with mode valve 230. ModeCmd Signal to mode valvesolenoid 238. Condition “ON” means the mode valve 230 is open.IsolationCmd Signal to isolation valve solenoid 244. Condition “ON”means the valve 242 is set to open. MainBypassCmd Signal to bypass valvesolenoid 252. Condition “ON” means the bypass valve 250 is set toclosed. ChargeBypassCmd Signal to charge valve solenoid 266. Condition“ON” means the charge by-pass valve 263 is set to closed. TransCaseCmdSignal to clutch valve solenoid 292. Condition “ON” means apply in anON/OFF mode. However, in one example discussed below involvingaggressive clutching, clutch 208 is a hydraulic clutch and the solenoidis a PWM solenoid. SwashEnable A flag related to enablement of a closedloop swash control for displacement of swash-plate 216. The flag isgenerally set to “TRUE” if the hydraulic drive system 102 is in normaloperation even if the swash-plate is in its neutral orientation. Thereare some cases where the flag is set to “FALSE” such as when theprecharge logic is utilized. (FIG. 6). In the example where prechargelogic is active the swash-plate is left in the pumping orientation eventhough there is insufficient pressure to maintain that position. If theflag were set to “TRUE” a FaultLevel would be set stating that theswash-plate cannot be “controlled” to the desired position. Thus, whenSwashEnable is set to “FALSE” the swash-plate 216 is uncontrolled.Therefore, it may be commanded to an orientation even though theconditions are not generally preferable for such an orientation.SwashOut The Set Point for the closed loop position control of theswash-plate 216. PositiveSwashLimit An output to pump-motor unit 217giving the maximum swash- plate angular displacement based on pump speedas measured by sensor 296. If a pump-motor normally has a possibledisplacement in the range of +/−fifteen (15) degrees, then the actualacceptable angular displacement will be decreased as pump speed goes upto minimize possible damage to the pump-motor. Typically a look up tableis used based on the mechanical operation of the pump. This outputrelates to the motoring mode and represents positive angulardisplacement. See FIG. 23. NegativeSwashLimit See PositiveSwashLimit.However, the output relates to the pumping mode and represents negativeangular displacement. See FIG. 17. SwashCalibration A flag associatedwith the calibration of the swash-plate 216 as part of the heuristicNeutralDriftCalibration 900 discussed below with respect to FIGS. 9 and10. The two conditions for the flag are “FALSE” and “TRUE”. The flag isset in operational realm 1108 of FIG. 11 when the motoring mode has beenexited. FailedEngagementCount A flag indicating engagement failuresrelated to clutch 208 and is used for fault detection and faultmanagement. See, for example, the discussion of flow-line 3012.AccPressMin Output from the temperature compensation heuristic 800discussed below with respect to FIGS. 7 and 8 and relates to the changein state for switch 284. When this pressure is measured by sensor 282during the motoring mode, the system 102 then exits the motoring mode.T_HLAid This represents an identification signal for various states asillustrated below, which is used for debugging. InletPress The inletpressure associated with clutch 208 measured by sensor 2928 when using ahydraulic clutch as part of a hydraulic circuit 2900 with aggressiveclutching, as discussed with respect to FIGS. 29 through 35 below.

An example of a determination of a swash-plate position commandSwashCmd, first discussed with respect to Table 3 above and used as aninput for controller 140, is now discussed with respect to FIG. 5. Ingeneral, an operator request for torque is translated into a swashdisplacement determination whereby the torque equals a pressure dividedby the product of hydraulic displacement and a constant. When there isno request for torque, the swash-plate position command shall be zero(0) degrees.

More specifically, there are two inputs into making a determination ofangular displacement of swash-plate 216. The first input is a driverrequest for torque, i.e., a torque command (Nm). The request for torquemay be as a result of either driver braking or driver acceleration.Possible inputs include that from brake pressure sensor 304 in FIG. 3,or the CAN message related to accelerator pedal position. The secondinput “AccPress_bar”, accumulator pressure (bar), is “AccPress,”measured from sensor 282 in FIG. 2 as shown at 504. The swash positioncommand shall be zero “0” degrees when the vehicle torque command iszero. Otherwise, in one illustrated approach:Swash Command=Torque Command Nm)/(K*Accumulator Pressure(bar))  Equation 1Where

K=250 cubic centimeters/revolution*TransferCaseRatio/2*pi*10*(15) deg,and for an exemplary transfer case, TransferCaseRatio=2.55.

Thus, an acceleration torque command results in a positive swash commandand a braking torque command results in a negative swash command.

Once a Swash Command is calculated, however, there has to be a potentialadjustment related to saturation for acceleration. In particular, theswash position command shall be saturated to a SwashLimit value, wherethe SwashLimit isif PumpSpeed<2500 RPM then SwashLimit=15 degif PumpSpeed>3000 RPM then SwashLimit=0if 3000 RPM>PumpSpeed>2500 RPM then SwashLimit decreases linearly from15 deg to 7.5 deg.  Equation 2

The values of 2500 RPM, 3000 RPM, 15 degrees and 7.5 degrees are merelyexemplary. The values will depend on the actual characteristics ofpump-motor 130, but are chosen to prevent inadvertent damage orinappropriate long-term wear issues to the pump-motor. Nevertheless, thevalues will generally be proportionally adjusted depending on thespecific pump-motor 217. For example 7.5 degrees is half of 15 degrees.

Similarly, once a Swash Command is calculated, there has to be apotential adjustment related to saturation for braking. The swashposition command shall be saturated to a SwashLimit value, where theSwashLimit isif PumpSpeed<2500 RPM then SwashLimit=−15 degif PumpSpeed>3000 RPM then SwashLimit=0if 3000 RPM>PumpSpeed>2500 RPM then SwashLimit varies linearly from −15deg to −7.5 deg.  Equation 3

As illustrated in FIG. 5, the torque command isHLADrivelinTorqueRequest_Nm, the accumulator pressure is “AccPress_bar”,constant K is C_SwashCalcGain, the saturation for acceleration isC_SwashCmdAccelLimit and the saturation for braking isC_SwashCmdBrakeLimit.

Once again, the values of 2500 RPM, 3000 RPM, −15 degrees and −7.5degrees are merely exemplary. The values will depend on the actualcharacteristics of pump-motor 130 as noted above.

Thus, a preliminary value will first be calculated in accordance withEquation 1 if thresholds related to the inputs for torque andaccumulator pressure are met. Then a determination related to saturationfor acceleration is made in accordance with Equation 2. The minimumvalue of the results of Equations 1 and 2 is determined. The minimumvalue is compared to the calculation for braking in accordance withEquation 3 and the maximum value is used. The resulting maximum value istypically used as the input for SwashCmd within controller 140 as shownin Table 3.

Under some circumstances, however, the input for SwashCmd is overwrittenby certain rules, often based on conditions being detected withinhydraulic drive system 102, such as when high pressure accumulator 138is first being charged at start up, or when they hydraulic drive systemis being shutdown.

Precharge Logic

The discussion above concerning the pump mode and the motoring mode ofhydraulic system 102 assumed that the hydraulic drive system 102 was ina normal operating state, A more detailed discussion of the exiting fromeither a normal motoring mode or a normal pumping mode is discussedbeginning with FIG. 11. However, when system 102 is not in such a stateit advantageous to precharge high pressure accumulator 138. In thecontext of the present description precharge relates to the need to addsome amount of hydraulic fluid so that the fluid has a sufficiently highpressure threshold to activate and otherwise operate the varioushydraulic controls (e.g., valve actuation) within the hydraulic drivesystem 102 that are powered by hydraulic fluid from the accumulator 138.

For example, when hydraulic drive system 102 does a controlled shutdownupon the turning off of a vehicle ignition, it is desirable to drain thehigh pressure accumulator 138 to inhibit undesirable wear to theaccumulator or other components within hydraulic drive system 102,provide ease of servicing and related issues. Accumulator 138 needs tobe re-pressurized upon re-activation of the hydraulic drive system 102.Similarly, while a temperature compensation methodology is discussedbelow with respect to the desirable operation of high pressure proximityswitch 284, at times the pressure within the high pressure accumulator138 may drop below a predetermined minimum threshold, again requiringprecharging high pressure accumulator 138

Operation of a precharge logic heuristic 600, entitledSwashPrechargeLogic, is illustrated with respect to FIG. 6. In general,the flag SwashEnable is initially set to “FALSE.” (Table 4). Theswash-plate 216 is set to a desired angular orientation in the pumpingdirection and the necessary valves are placed in the proper orientationto permit the pumping cycle to take place even as the vehicle 100 isactually motoring. Thus, when precharging is taking place, some of theincreased level of energy generated by the engine 112 passing throughdrive-line 116 as mechanical energy is diverted to the hydraulic drivesystem 102 as hydraulic energy. Once precharging takes, place, however,normal motoring and pumping modes take place as discussed in greaterdetail herein beginning with FIG. 11.

Precharge logic heuristic is required because there is no control overthe swash-plate 216 when the accumulator 138 is discharged. As notedabove, control of the swash-plate 216 requires hydraulic fluid from theaccumulator 138 to operate. Hence, it is a type of boot-strapping. Ifthere were adequate swash control with a discharged accumulator 138, itwould not be as inefficient to just wait until a first braking event forvehicle 100 where the hydraulic drive system 102 is already designed tocharge the accumulator 138.

An entry point 602 to the SwashPrechargeLogic heuristic 600 isillustrated in FIG. 6. Preferably, heuristic 600 is always active withincontroller 104 and available for use when necessary by the system 102.Various operational realms associated with SwashPrechargeLogic heuristic600 are represented by the encircled regions 602, 604, 606, 608, 610.

In the flows that are illustrated in the various figures, the term“operational realm” refers to a system state. However, additional statescan exist within each of the operational realms. Moreover, yet otherstates can exist within the states described below. Thus, the terms“operational realm”, “state” and “box” are used to provide guidanceconcerning the level being discussed within hydraulic drive system 102for the indicated topic. States are described within operational realmsand boxes are described within states. If an encircled region for anoperational realm, state or box is in bold, typically there is a moredetailed discussion in an accompanying figure. Within an operationalrealm, state or box, it is possible to have an operation, which isrepresented by a rectangular box within the indicated flow. Often, theoperation is then discussed in more detail in a separate figure,particularly when the rectangle is bold.

A title for each operational realm is provided in the first line ofinformation in each operational realm 604, 606, 608, 610, and 612. Thesecond line, entitled “entry: T_HLAP_id” is used for debugging purposesand need not be discussed further herein. The other lines of informationin each box provide conditions to be applied when in the operationalrealm and will be discussed as appropriate. The term “during:”represents an instruction to perform the processing indicating by theinstruction following the “:” while in the operational realm representedby the relevant encircled region 604, 606, 608, 610, and 612. Morespecifically, the term “during:” refers to actions that are executedwhen a state receives an event while it is active with no validtransition away from the state. Finally, the term “exit:” refers toactions executed when a state is exited as the result of a transitiontaken away from the state.

Between each of the operational realms 604, 606, 608, 610, and 612 areone or more arrowed flow-lines, labeled respectively as 614, 616, 618,620, 622, 624, 626 and 628. Each of the flow-lines has conditionsassociated with it that are generally associated with Boolean operators.

Boolean operators are represented in generally known ways. For example,the operator “AND” is represented by the designation “&&”; the operator“OR” is represented by the designation “∥”; the operator “EQUAL TO” isrepresented by the designation (“==”; the operator “NOT EQUAL TO” isrepresented by the designation “˜=” the operator “LESS THAN” isrepresented by “<”; the operator “GREATER THAN” is represented by “>”;the operator “LESS THAN OR EQUAL TO” is represented by the operator“<=”; the operator “GREATER THAN OR EQUAL TO” is represented by theoperator “>=”. The designation “ . . . ” simply indicates that theconditions that need to be satisfied are continued on the next line oftext. The conditions associated with a particular flow-line arebracketed by square brackets “[ ]”.

When entering one of the operational realms, states or boxes discussedin more detail below, the term “entry:” refers to actions executed whena particular “operational realm”, “state” or “box” is entered as theresult of a transition taken to that state. The use of other Booleanoperators or flow commands and a more detailed explanation of FIG. 6 andthose of a similar nature also set forth herein will be clear to anindividual of ordinary skill with respect to the program known as“StateFlow” and more particularly to version 6.4 of the program.“StateFlow” is provided by The MathWorks, Inc., 3 Apple Hill Drive,Natick, Mass. 01760-2098. The user guide and related reference materialsfor “StateFlow” and more particularly version 6.4 of the program areincorporated herein by reference. Additional information can also belocated at the URL http://www.mathworks.com/products/stateflow/. Thelogic associated with FIG. 6 applies equally to other figures discussedbelow with respect to other aspects of hydraulic drive system 102.

When hydraulic drive system 102 is activated such as after a shutdown ofvehicle 100 and the vehicle ignition is turned on as captured by thecontrol logic of controller 140 in FIG. 4, controller 140 invokesSwashPrechargeLogic heuristic 600 at point 602. The SwashPrechargeLogicheuristic 600 then in turn enters the operational realm 604, entitledSwashDrift. A flag T_SwashDrift is set to “TRUE”. In general terms andas also illustrated by the command SwashCmdPrechLogic=SwashBrakeLimitusing the variable SwashCmdPrechLogic, when the flag is set to “TRUE”, acommand is sent to the swash-plate 216 by controller 140 asking it to goto a maximum available angular displacement in the negative direction tofacilitate pumping. In one exemplary embodiment the value is negativefifteen (−15) degrees, but the maximum available angular displacementwill depend on characteristics of the pump-motor unit 217 and the valueof SwashBrakeLimit as set forth in Table 3.

Similarly, the terms MainBypassCmd, IsolationCmd and ChargeBypassCmdhave already been discussed with respect to Table 4 and they are set to“ON” as illustrated in FIG. 6. In summary, when solenoid 252 is “ON,”hydraulic fluid cannot pass from the “high pressure” side to the “lowpressure” side using by-pass valve 246, which is forced closed. Whensolenoid 244 is “ON,” fluid may pass in either direction throughisolation valve 242, not being limited to one way movement towardaccumulator 138 by way of the illustrated check valve. When the bypasssolenoid is “ON”, the charge by-pass valve 262 is forced closed so fluidpassing through the charge pump 204 does not simply go back intoreservoir 134 via conduit 215.

Further, when in operational realm 604, when an operator of vehicle 100commands an acceleration, the clutch 208 is activated, the vehiclestarts to move, the pump-motor 217 and charge pump 204 begin to rotateabout shaft 206 and precharging begins.

As precharge pumping takes place while in operational realm 604, fluidflows from reservoir 134, along conduit 268, through charge pump 204,along conduit 270, through pump-motor 130, along conduit 248, throughmode valve 232 against the pressure of its spring, into conduit 223 andfinally into the high pressure accumulator 138.

Heuristic 600 moves from operational realm 604 to operational realm 606,entitled Delay2, by way of flow-line 614. This transition occurs whenone of the acceptable indicated conditions associated with flow-line 614are met. In a first set of acceptable conditions, accumulator pressureAccPress must be greater than the constant C_AccPressStartup, and thestate of high pressure accumulator switch AccState must equal “notempty”. In one illustrated embodiment, the constant C_AccPressStartup isone-hundred bars. A second acceptable condition is that the sensorreading SwashFbk is less than equal to minus five degrees as measuredfrom sensors 218 and/or 220, A third acceptable condition is that themode valve is not actually closed (i.e., is set to “ON”). A finalacceptable condition is that the speed PumpSpeed of pump-motor unit B17measured from sensor 296 is less than 200 RPM. The pump speed is usedwith heuristic 600 since a minimum speed is required for pressureincrease within the high pressure accumulator 130 to take place. Theactual speed required will vary with characteristics of the pump-motor130, charge pump 204 and other aspects of system 102.

When high pressure accumulator 138 begins to fill using theSwashPrechargeLogic heuristic 600, the valve associated with switch 284only begins to open when the pressurized flow along conduit 223 beginsto open it. This is done to protect the bladder associated withaccumulator unit 280 such as when a pressurized gas arrangement isutilized. In one approach accumulator unit 280 has a bladder thatcontains nitrogen. However, even if the valve opens, the switch will notchange states between “accumulator empty” and “accumulator not empty” byway of AccState (as described in Table 3) until a minimum thresholdpressure is met. During normal motoring and pumping modes switch 284will stay in the “accumulator not empty” state because the minimumthreshold pressure continues to be met. A different heuristic isdiscussed below with respect to FIGS. 7 and 8 that helps to ensure thatthe switch state does not change even with changes in temperature. Ifthe heuristic fails, however, then the SwashPrechargeLogic heuristic 600becomes active.

Once in realm 602, a timer is set during which solenoid 252 is set to“ON,” the isolation solenoid 244 is set to “ON,” but the charge by-passsolenoid 266 is set “OFF.” Thus, fluid can now pass into reservoir 134through conduit 215 from conduit 270. Other time periods of delay can beused. The use of five milliseconds is merely exemplary. In selecting atime period for delay it is important to have a set period of delay toeliminate potential false signals or noise on the various switchindicators before moving into operational realm 608, or if more time isrequired to build up accumulator pressure. Thus, as illustrated, it ispossible to pass either back to operational realm 604 or move on tooperational realm 608 from operational realm 606.

System 600 will move back to operational realm 604 as represented byflow-line 616 if the following conditions are met. First, either theaccumulator pressure must be less than the constant C_AccPressStartup,or switch 284 must be in the accumulator empty state. If eithercondition is met and (i) the angular displacement of swash-plate 216 isgreater than negative five (5) degrees; (ii) the mode valve 232 isclosed, meaning that solenoid 238 is not activated, and (iii) the speedof motor-pump unit 217 is greater than a predetermined value such 500RPM as measured by sensor 296, then the position of swash-plate-216should be adjusted. A SwashDrift correction is again required atoperational realm 604.

Once the timer shows a time greater to or equal to 0.2 seconds withoutany conditions requiring a return from operational state 606 tooperational state 604 by way of flow-line 616 then, as represented byflow-line 618 the system 600 moves to operational realm 608, entitledHoldPosition. The time period of 0.2 seconds is merely exemplary. It isselected as a long enough time, however, to provide confidence thatfurther use of the SwashDrift operational realm 604 is not required.

At operational realm 608 the flag T_SwashDrift is set to “FALSE.” Theflag prevents any specific control of the swash-plate 216. Then, whilein the operational realm 608, the variable SwashCmdPrechLogic is setequal to the sensor reading SwashFbk from sensors 218 and/or 620. Whilein this operational realm the SwashPrechargeLogic heuristic 600 waitsuntil the high pressure accumulator starts to fill and becomepressurized. Thus, the flag T_SwashDrift is typically set to “FALSE” fornormal motoring or pumping operations. However, as with the flagSwashEnable (Table 4), there are times when it is desirable to have anoverride of the normal operation of hydraulic drive system 102 betweenthe motoring mode and the pumping mode. When T_SwashDrift is set to“TRUE,” precharging takes over and sets both the valves and theorientation of swash-plate 216.

Generally control will pass from operational realm 608 to operationalrealm 610, entitled Normal, along flow-line 620. As shown in associationwith flow-line 620, control passes between operational states 608 and610 when the accumulator pressure AccPress is greater than constantC_AccPressStartup and the switch 284 is in the accumulator not emptystate.

Normally, while the vehicle 100 is operating normally between variousmotoring and pumping modes, system 600 will stay in operational realm610 and the variable SwashCmdPrechLogic will equal SwashOut1. SwashOut1is preferably set at a predetermined constant rate, which applies whenhydraulic drive system 102 moves out of pumping or motoring mode and isused to make sure that the displacement of swash-plate 216 does not varytoo quickly.

SwashPrechargeLogic heuristic 600 will leave operational state 610 toreturn to HoldPosition operational realm 608 by way of flow-line 622only if one of two conditions is met. The first condition is met if thepressure of accumulator 138 becomes less than the constantC_AccPressStartup minus a predetermined offset. In the illustratedsystem the offset is twenty (20) bar. The second condition is met ifhigh pressure accumulator proximity switch 284 enters the accumulatorempty state.

Apart from transition to operational realm 610, there is a second way toleave the HoldPosition operational realm 608, i.e., by way of flow-line624. Such transition occurs only if controller 140 perceives a problemwith pressure within the high pressure accumulator 138, e.g., theaccumulator is the state “accumulator empty” or below the pressurerepresented by C_AccPressStartup. The conditions associated withflow-line 624 are the same as for flow-line 616 representing atransition between operational realms 604 and 606.

Operational state 612 is essentially a built-in time delay mechanismwhere, by of example, a time delay variable may be set to five (5)milliseconds. Control will return back to the HoldPosition operationalstate 608 if the conditions of flow-line 626 are met. Again showingsymmetry, the conditions of flow-line 626 are the same as for flow-line614 between operational states 604 and 606. On the other hand, ifcontroller 140 perceives problems with the system 102 having lost thenecessary minimum accumulator pressure for high pressure accumulator138, then after a predetermined period of time, illustrated as greaterthan or equal to one second, control will return to operational realm604. The entire process will begin again, including the forced movementof the swash-plate 216 to the necessary angular displacement and thevalves being set to maximize pressure buildup when mechanical energy isconverted to hydraulic energy by way of charge pump 204 and pump-motor130.

Temperature Compensation for Pressure Limits

As discussed in detail above, the SwashPrechargeLogic heuristic 600 isused to precharge high pressure accumulator 138 to at least a minimalpressure such that the high pressure proximity accumulator switch 284changes state from “accumulator empty” (ACC_EMPTY) to “accumulator notempty” (ACC_NOT_EMPTY) by way of variable AccState. It is desirable thatSwashPrechargeLogic heuristic 600 only be used only upon the turning onof the ignition of vehicle 100 and initial activation of hydraulic drivesystem 102, which is necessary because accumulator 138 has been bled toatmospheric pressure when the ignition was last turned off. Such ableeding is performed for various reasons, including the desire tomaximize the operational life of the accumulator. Completely bleedingthe accumulator 138 is not desired, however, when hydraulic drive system102 is in its normal operational state.

There is an appropriate cut off point for AccState where a majority ofthe appropriate volume of hydraulic fluid has been removed from the highpressure accumulator unit 280 such that the removal of any additionalvolume of fluid will result in a precipitous pressure drop, therebyrequiring the use of heuristic 600 to recharge the high pressureaccumulator 138. A pressure point is selected to remove as much volumeof fluid as possible for a given temperature without inadvertentlypermitting the precipitous drop in pressure, thereby creating the needto continuously invoke heuristic 6100 during normal operation of system102. Thus, as noted above and in Table 3, it is desired to avoid achange of state AccState for accumulator switch 284 during normaloperation of hydraulic drive system 102 between motoring mode andpumping mode.

FIG. 7A shows the desired changes in pressure for sensor 282 duringnormal motoring and pumping modes, and transitions therebetween, by wayof line 702. At time to motoring begins and the pressure of accumulator138 is at its maximum level. As motoring takes place, bleedingpressurized fluid from the accumulator, the pressure begins to drop.Once the pressure reaches a predefined threshold motoring stops withoutthe accumulator switch changing state from “accumulator not empty” to“accumulator empty” as shown at time t1. Then, between time t1 and timet2, neither motoring nor pumping takes place within hydraulic drivesystem 102 although vehicle 100 itself is moving. However, at some pointvehicle 100 begins to decelerate, invoking the pumping mode at time t3.Pumping continues until the pressure of fluid stored in accumulator 238is generally the same as that at time t0. The system recycles back totime to and the process begins again.

Unfortunately, however, at times, pressure is not correctly maintained.Instead of maintaining at least a minimal pressure as shown betweentimes t1 and t2, the accumulator abruptly loses all of its pressureessentially all at once after a certain minimum pressure level isreached as shown by line 704 and point 706. The reason for such pressureloss is generally that too much hydraulic fluid was permitted to leavethe accumulator unit 280. Under such circumstances, it takes time andenergy to precharge the accumulator unit 280 using heuristic 600 asdiscussed above, which decreases the operational efficiency of system102 because normal motoring and pumping is not possible when prechargingis taking place. Moreover, as noted above, there is no control ofswash-plate 216 if there is no pressurized hydraulic fluid available.

In practice, the conditions under which proximity switch 284 shouldchange state to avoid complete bleeding of high pressure accumulatorunit 280 is not constant, but varies significantly with temperature. Asillustrated in FIG. 7B, various graphs of pressure versus volume showthat as temperature increases, the less volume of hydraulic fluid thatcan be stored at the same pressure.

Thus, it has been found that, to minimize the need to invokeSwashPrechargeLogic heuristic 600, a mechanism is necessary to adjustparameters associated with the activation of switch 284 between thestates “accumulator empty” and “accumulator not empty.” Such adjustmentaccommodates for pressure changes as a result of temperature changes,thereby affecting the amount of volume that can be removed at any onetime from high pressure accumulator unit 280.

Measuring temperature in association with the use of accumulator 130,including high pressure sensor 282, high pressure proximity accumulatorswitch 284 and accumulator unit 280 has been problematic. In practice,as mentioned above, it has been difficult to determine a real-timetemperature reading that is capable of determining when the maximumvolume of hydraulic fluid can be removed from accumulator 138 withoutthe pressure dropping precipitously.

In general terms, pressure is monitored within hydraulic drive system102 as follows. Pressure sensed by sensor 282 is stored at the time thatswitch 284 changes state and opens to permit the commencement of themotoring mode. This is shown at time to in FIG. 7A. The pressure sensedby the sensor 282 is again stored when switch 284 changes state between“accumulator not empty” and “accumulator empty” at time t1, particularlyif there is an undesirable precipitous drop in pressure. Under such acircumstance, an offset for the pressure is added as a hysteresis andthe new and higher value of pressure is used as the new pressure limitfor the change of state for switch 284 so that the associated valveshuts off before the volume of fluid becomes undesirably low. Thus, thepressure at which motoring stops because of a change of pressure iscompared against a threshold pressure that can be adjusted based onchanging conditions.

Such an approach has been found to be more accurate to changingconditions then simply measuring fluid temperature in an attempt todetermine amount of acceptable volume removal from the high pressureaccumulator 130. Nevertheless, the use of temperature such as thatmeasured by sensor 288 for reservoir 134 does provide some guidance.Particularly when a vehicle 100 is first started and system temperatureis generally constant, the temperature information is preferably used toprovide an initial pressure for setting the change in state of switch284, which is then adjusted as temperature increases over time. If thetemperature goes down for same reason (e.g., idling for a period oftime), it is also possible to reduce the pressure level for switchactivation at time t1 accordingly.

A HighAccPressMinLimits heuristic 800 is illustrated in FIG. 8.Heuristic 800 begins at entry point 802 and includes operational realms804, 806, 808, and 810.

Operational realm 804 is entitled FootValveOpen. The variableAccPressMin is equal to the maximum value of either the prior iterationof AccPressMin or a preset constant, illustrated in the example as 135bars, which is roughly atmospheric pressure at an ambient temperature oftwenty (20) degrees Celsius. AccPressMin should reflect, however, theminimum acceptable value of pressure for hydraulic system 102. Forexample the initial minimum pressure is also based on the prechargepressure designed for accumulator unit 280. Thus, the “max” operation istypically used to prevent accidental over-compression of a bladderassociated with high pressure accumulator unit 280 when a gasaccumulator with bladder is utilized.

AccPressMin is defined above in Table 4. The initial default value ofAccPressMin may be changed depending on the value of the temperaturemeasured by a sensor such as sensor 288, and will typically be higher asthe temperature is higher. Thus, in some approaches, a lookup table isprovided and the minimum value of 135 bars is adjusted upwardly as thetemperature measured by sensor 288 increases.

Next the variable MinAccPressToMotor is set equal to the variableAccPressMin plus a predetermined offset. In the exemplary flow, theoffset is 15 bars. MinAccPressToMotor is defined in Table 4 above. It isused to help determine when system 102 should enter the motoring mode.

Control passes from operational realm 804 to operational realm 806,entitled TimeDelay2, when high pressure proximity accumulator switch 284changes state to “accumulator empty” and closes high pressureaccumulator 280 as shown by flow-line 812. Operational realm 806provides a time delay to filter out false signals. In the illustratedheuristic, the a time variable is set to five milliseconds. If it turnsout that there was a false signal and switch 284 has not changed stateto “accumulator empty,” then control passes back to FootValveOpenoperational realm 804. Preferably, hydraulic drive system 102 shouldnever leave operational realm 804 during normal operation of the systemfor the reasons noted above. However, if it does, e.g., because anadjustment is required because of changes in temperature, the discussionthat follows addresses the actual pressure adjustments that need to bemade in one exemplary approach using heuristic 800.

Thus, control passes from operational realm 806 to operational realm808, entitled FootValveClosed, if the time delay is greater or equal to0.5 seconds and the accumulator switch 284 has entered the state“accumulator empty,” as shown by flow-line 816.

In FootValveClosed operational realm 808 a temporary value is set to thecurrent accumulator pressure as measured by sensor 282. This temporarypressure value continues to update until the valve associated withswitch 284 changes state and opens. In other words, control of heuristic800 stays within operational realm 808 until switch 284 changes state to“accumulator not empty” as shown by flow line 818. The pressure measuredat the time of such a state change is captured in the variableHighAccPress_temp.

Flow-line 818 connects to operational realm 810, entitled TimeDelay1,which performs the same operation as in operational realm 806 althoughthe time may not be identical. If it turns out that there was a falsesignal and the accumulator state should be “accumulator empty” thencontrol passes back to operational realm 808.

Otherwise, if the time is greater than 0.5 seconds and the state ofaccumulator switch 284 is “accumulator not empty” then the variableAccPressMin is set to the value of AccPress_Temp when in operationalrealm 808 and then increased by a preset amount, illustrated as 5 bars.This is shown in flow-line 822, passing control from operational realm810 back to FootValveOpen operational realm 804. As noted above,ideally, control will remain within operational realm 804 until furthertemperature compensation because of pressure limits is required.

Compensation for Swash Neutral Drift

As noted above, when hydraulic drive system 102 is discharging (e.g., ina motoring mode) the swash-plate 216 is moved in a positive angulardisplacement, up to a maximum angle such as fifteen (15) degrees.Similarly, when the hydraulic drive system 102 is charging (e.g.,precharging or in a normal pumping mode), the swash-plate is moved in anegative angular displacement up to a maximum angle such as fifteen (15)degrees. When the system is in a neutral position, however, neitherpumping nor motoring, ideally the swash-plate 216 is in a neutralposition of zero displacement, which is set at zero (0) degrees. Whenthe swash-plate 216 is at zero degrees it is considered at an absoluteneutral position.

In practice, however, either the swash-plate 216 or the sensors 218and/or 220 that measure the positioning of the swash-plate 216 have atendency to drift and a compensation has been found beneficial tocalibrate the swash-plate and sensors to adjust for the drift so thatthe overall system works more efficiently in overall operation. In thediscussion that takes place below reference to drift of the swash-plate216 also refers to potential issues with sensor signal drifting that canresult from sensor readings as well

Operation of a heuristic called NeutralDriftCompensation 900 isillustrated in FIGS. 9 and 10. Heuristic 900 includes operational realms904, 906 and 906. Details of operational realm 906 are explained ingreater detail in FIG. 10. As discussed in more detail with respect toFIG. 11, adjustment for drift of the swash-plate 216 preferably takesplace after the motoring mode is terminated, as shown with respect tothe transition from operational realm 1110 to operational realm 1108 byway of flow-line 1130. The conditions associated with flow-line 1130 inaddition to those associated with the exit of the motoring mode arediscussed below with respect to operation 1112 in FIG. 11 and FIG. 15.

In order for drift compensation to take place, one of the conditionsthat needs to be satisfied is that the mode valve 232 needs to be open.Valve 232 is open when hydraulic drive system 102 is in motoring mode.Controller 140 then checks for a flow through pump-motor unit 217 in themotoring direction to see if there has been any drift.

NeutralDriftCompensation heuristic 900 begins at entry point 902, thedefault state, entitled NotEnabled. Control remains within operationalrealm 904 until the conditions of flow-line 908 are met. First flagSwashCalibration, discussed above as one of the output variables fromcontroller 140, and must not be equal to “FALSE.” A “FALSE” value of theSwashCalibration flag indicates that (i) the hydraulic drive system 102has just exited from motoring mode; (ii) the mode valve 232 is stillopen to permit flow to go from accumulator 138 to the reservoir 134; and(iii) there is sufficient vehicle speed for an effective neutral driftsensing. Second, a reading SwashFbk from sensor 218 and/or 210 must beless than a constant C_SwashAccelIdleBand and greater than a secondconstant C_SwashBrakeIdleBand, indicating that the swash-plate 216 isbelieved to be in the neutral position. In one illustrated approach,constant C_SwashAccelIdleBand is +0.25 degrees, while constantC_SwashBrakeIdleBand is −0.25 degrees. If all three conditions are met,then using flow-fine 908, control passes from operational realm 904 tooperational realm 906, entitled delay. On the other hand, even if theflag SwashCalibration has been set not equal to “FALSE”, control willnot pass to the next operational realm if the position of swash-plate216 is within an operational band extending between constantC_SwashBrakeIdleBand and constant C_SwashAccelIdleBand. An exemplaryvalue of C_SwashAccelIdleBand is one-half (0.5) degree. Use of theconstant C_SwashAccelIdleBand represents a recognition that it isunrealistic to expect the swash-plate 216 to remain exactly at singlepoint of zero (0) degrees even when in neutral and properly calibratedfor drift. Further, the band of acceptable “neutrality” may be easilyadjusted as a result of hardware and environmental issues, or specificperformance considerations. For example, the constants may be changedunder certain operational protocols as appropriate.

Once in Delay operational realm 906, a time delay is imposed inaccordance with the variable LOOP_TIMESLOW, which can vary asappropriate. The delay is imposed in operational realm 906 to permit theswash-plate 216 to settle in a rest position before starting anadjustment calculation as discussed with respect to operational realm908. As shown by flow-line 910, an adjustment to swash-plate 216 willnot be performed if one of three indicated conditions is met. First ifthe flag SwashCalibration is set as “FALSE,” then control returns fromDelay operational realm 906 back to NotEnabled operational realm 902.Control also returns from Delay operational realm 906 back to NotEnabledoperational realm 902 if the sensor readings from sensors 218 and/or 220are either greater than constant C_SwashAccelIdleBand or less thanC_SwashBrakeIdleBand, However, a multiplication factor of 1.5 isillustrated for the indicated conditions to avoid the need to enter intooperational realm 908 on a too frequent basis. Under some circumstances,however, there will be no offset. The offset is merely shown to beillustrative of one approach.

On the other hand, if the conditions associated with flow-line 910 arenot met, but the delay time is greater than or equal to the constantC_SwashCalibrationDelayTime as shown by flow-line 912, control passes tooperational realm 908, entitled Adjustment. The value of the constantwill depend on operational, environmental, and hardware characteristicsrelated to hydraulic drive system 102, but should desirably made asreasonably short as possible.

Control will pass from Adjustment operational realm 908 back toNotEnabled operational realm 902 by way of flow-line 914 if the sameconditions that are discussed with respect to flow-line 910 are met withrespect to flow-line 914. In some approaches, portions of theconditions, such as the offset value (here, 1.5 for both), may bedifferent.

The operations that take place within operational realm 908 areillustrated in FIG. 10. The operational realm is entered at point 1002where it goes into a state 1004 entitled Time1. A pressure reading istaken that is reflected as HighP at some appropriate point withinhydraulic system 102, such as, for example, using AccPress_bar from highpressure accumulator sensor 282. The value of the pressure is savedusing variable HighP_t1 and a timer starts such as that in operationalrealm 906. Once the timer has a value greater than or equal to theconstant C_PressureChangeTime as shown by flow-line 1006, control movesfrom state 1004 to state 1008 entitled Time2. Typically, the constantC_PressureChangeTime is set on the order of a second or so. In state1008 the pressure from the same sensor such as sensor 282 is againmeasured and saved using the temporary variable HighP_t2. The twotemporary variables representing the pressure at time 1 within stateTime1 and at time 2 within state Time2 are then compared.

If there is a change in pressure between the two pressure readings thenthere is flow. If there is flow then the pump-motor unit 130 is actuallynot in neutral. If the change in pressure between the two times ispositive, meaning that a pressure discharge is taking place (e.g.,motoring), then the operational realm 908 needs to adjust theswash-plate 216 in the negative direction. However, if the change ofpressure is negative, then a charging operation is taking place (e.g.,pumping) and the operational realm needs to adjust the swash-plate 216in the positive direction. The process needs to continue untiloperational realm 908 is exited by one of the conditions associated withflow-line 914 in FIG. 9 being satisfied as discussed above.

More specifically, the rest of the adjustment process is illustrated byway of flow-line 1010, condition point 1012, flow line 1014, conditionpoint 1016, flow-line 1018, condition point 1020, and flow-line 1022,finally returning to state 1008.

As shown by flow-line 1014 between condition points 1012 and 1014, ifthe change in pressure is greater than the constantC_DecreaseSwashPressureChange, then the swash-plate 216 is adjusted aminute amount Angle1_Neutral_Bit in the negative direction asrepresented by the condition “−=1”. In contrast, as shown usingflow-line 1018 between condition points 1018 and 1020, if the change inpressure is less than the same constant, then the angular displacementof the swash-plate 216 is adjusted by the amount represented by thevariable Angle1_Neutral_bit in the positive angular direction, asrepresented by the condition “+=1”. Typically, Angle1_Neutral_Bit is setto be on the order of 0.04 degrees, meaning that the change in angulardisplacement is very small for each iteration of the adjustment process.If the change in angular displacement is insufficient because of timeconstraints, the value can be increased accordingly.

Exiting from Motoring Mode and Pumping Mode

FIGS. 11 through 28 concern the movement of hydraulic drive system 102from a neutral state to either one of a pump mode or a motoring mode innormal operation, and then the exiting from each of the modes back tothe neutral state. If the exiting is due to an operator command, thepath followed uses a constant rate methodology as described in moredetail below. However, if the exiting is due to the hydraulic drivesystem 102 approaching a condition limit, typically based on either thespeed of pump-motor 130 or measured pressure of accumulator 138, thenthe path followed uses a variable rate methodology, which has beentermed “soft exit”.

By using the term constant rate we mean that there is so much a changein the displacement of swash-plate 216 per second (e.g., 15 degrees in500 msec).

On the other hand, when timing is an issue, different metrics, namelythe concern with both pressure (bar) and pump speed (RPM), is used. Byusing the term variable rate we mean that there is so much a change inthe displacement of swash-plate 216 per change in pressure associatedwith accumulator 138 or a change in pump speed of pump-motor 130.

To facilitate the discussion that follows, it is to be assumed thathydraulic drive system 102 exits the pumping mode at a constant ratewhen an operator of vehicle 100 is done braking (e.g., the operator'sfoot removed from the brake pedal). Hydraulic drive system 102 exitsbraking at a variable rate when the maximum amount of hydraulic energyhas been stored in the system or if another condition specific to thesystem has been met.

Hydraulic drive system 102 exits the motoring mode at a constant ratewhen an operator command causes the exit (e.g., the foot is removed fromthe gas pedal). Hydraulic drive system 102 also exits motoring when thesystem 102 has exhausted the stored energy available to promoteacceleration.

Exiting the pumping mode at a constant rate is generally slower thenexiting at a variable rate. Because performance issues associated withhydraulic drive system 102 are not the limiting factor (e.g., there isno issue with respect to the pressure stored or remaining in thesystem), the variable rate can be based on time. Other factors alsoinfluence both pressure and speed.

When using variable rate exiting, however, as the limit is approachedthen less displacement of swash-plate 216 is allowed. Generally, thelimit is reached at the same time zero displacement is reached. In thisway there is a gradual or “soft exit”. However, such an exit isnonetheless faster than constant rate exiting. Both the constant rateexit state and the variable rate state, however, represent transitionsfrom either a motoring mode or a pumping mode and the neutral state.

More specifically, it is desirable to undertake a soft exit from amotoring mode when the pressure associated with high pressureaccumulator 138 drops to a predetermined level as discussed above, forexample with respect to FIG. 7A, or if the pump-motor unit 217 exceeds adesired pump speed limit. Thus, both conditions (pressure of highpressure accumulator 138 and speed of pump-motor unit 217) are monitoredcarefully. Similarly, to exit pumping mode, a maximum desirable pressuremust be reached for high pressure accumulator 138 or the speed ofpump-motor unit 217 exceeds a threshold value. In either case, however,unless there are extenuating circumstances such as a fault, it isdesirable to exit out of the pumping mode or the motoring mode in amanner that maximizes torque, but also is accomplished in a manner thatis not abrupt or disruptive to long-term operation of hydraulic drivesystem 102. Moreover the transition of hydraulic drive system to theneutral state should permit engine 112 to smoothly adjust for thechanging torque load. Such a transition is accomplished through acontrolled adjustment or modulation of swash-plate 216, taking intoaccount the current pressure and the end pressure to reach a neutraldisplacement. Temperature can also play a factor. Nevertheless,preferably the swash-plate 216 is gradually de-stroked.

FIG. 11 represents an example of a hydraulic drive system 102 when it isin an engaged state 1100, represented by the term Engaged. When enteringengaged state 1100, the flag SwashEnable is set equal to “TRUE” topermit operation of a close loop swash control for displacement ofswash-plate 216. A variable called DisengageCmd is set to “FALSE” withincontroller 140. Further the variables IsolationCmd and MainBypassCmd areboth set to condition “ON,” meaning that the isolation valve 242 is setto open while the bypass valve 250 is set to closed. While in engagedstate 1100, certain actions are executed when the state receives anevent while it is active with no valid transition away from the state.These actions include setting SwashEnable to condition “TRUE”. Further,an appropriate signal is set to clutch valve solenoid 290 when the flagassociated with TransCaseCmd is set to “ON”. Finally, both IsolationCmdand MainBypassCmd are maintained in the “ON” condition.

Engaged state 1100 is entered by way of entry point 1102. There arevarious operational realms 1104, 1106, 1108, and 1110 associated withengaged state 1100. There are also various operations 1112, 1114, 1116,1118, and 1120 that are called while in engaged state 1100.

Once engaged state 1100 is entered by way of entry point 1102, controlpasses first to operational realm 1104, entitled PumpInNeutral. While inthis operational realm the variable SwashOut is set equal to “0,”meaning that the set point for the swash-plate is at a neutraldisplacement of zero (0) degrees. The mode valve 230 is set to a closedposition by the variable ModeCmd being set to the condition “OFF,” whilethe charge by-pass valve 263 is set to an open position by the variableChargeBypassCmd being set to the condition “OFF”. Flags associated withvariables BrakeCmd and AccelCmd are both set to “FALSE,” meaning thatneither motoring nor pumping should take place. The variableDisengageCmd is set to “FALSE”.

Further, operation 1116, entitled EvalBrakeTorqueAvail, is executedwithin operational realm 1104. As illustrated in an exemplary manner inFIG. 12, operation 1116 is entered by way of entry point 1202. As shownby flow-line 1204 if three conditions are met then the variableNegativeSwashLimit is set to equal to the value associated with thevariable SwashBrakeLimit, meaning that the hydraulic drive system 102has braking torque available and can go into pumping mode upon receivingan operator command. The variable SwashBrakeLimit is discussed above,including with respect to Table 3. Otherwise, if any one of theconditions is not met, then the variable NegativeSwashLimit is set equalto “0,” as shown by flow-line 1206, meaning that the hydraulic drivesystem 102 cannot deliver braking torque. The three conditions are that(i) the pressure measured by sensor 282 must be less than the value setby MaxAccPressToBrake; (ii) the speed of pump-motor 130 must be greaterthan the constant represented by C_MinPumpSpeedToBrake, which representsthe minimum pump speed that is acceptable to permit the pumping mode;and (iii) the reservoir level associated with the measurement of sensor286 must be greater than the constant C_MinOilLevelToBrake, whichrepresents the minimum level of hydraulic fluid in low pressurereservoir 134. The value of the two constants will be differentdepending on the specific hydraulic drive system 102, but are set sothat if the conditions are met, the pumping mode may be appropriatelyentered. As noted above with respect to Table 3, the value ofMaxAccPresstoBrake is related to temperature.

If the conditions of flow-line 1204 are met, then if the variableSwashCmd is less than the constant C_SwashBrakeIdleBand, indicating thatan operator braking command is present, then the flag BrakeCmd is set to“TRUE,” as shown by flow-line 1208. This means that the hydraulic drivesystem 102 is commanded to transition to a pumping mode (i.e., a brakingstate). Otherwise, the flag BrakeCmd is set to “FALSE” as shown byflow-line 1210, and the hydraulic drive system 102 will remain inPumpInNeutral operational realm 1104. SwashCmd is an input resultingfrom a determination of a swash plate position command, discussed withrespect to Table 3 and FIG. 5. The constant C_SwashBrakeIdleBand isdiscussed with respect to FIG. 9.

Operational Realm 1104 also executes the operation 1118, entitledEvalAccelTorqueAvail. As illustrated by way of example in FIG. 13,operation 1118 is entered by way of entry point 1302. For the variablePositiveSwashLimit to be set equal to the value associated with thevariable SwashAccelLimit, four conditions, listed below, must besatisfied. Otherwise, i.e., if any one of the conditions is not met,then the variable PositiveSwashLimit is set equal to “0” as shown byflow-line 1306, indicating that the hydraulic drive system 102 cannotdeliver an accelerating torque (while in braking). The variableSwasbAccelLimit is discussed above, including with respect to Table 3.The first condition is that the accumulator pressure 282 must be greaterthan a value associated with the variable MinAccPressToAccel. As notedabove with respect to Table 3, the value of MinAccPressToAccel isrelated to temperature. The second condition is that the speed ofpump-motor unit 217 must be greater than constant C_MinPumpSpeedToAccel(discussed with respect to FIG. 12). The third condition is that thespeed of pump-motor unit 217 must be less than a constantC_MaxPumpSpeedToAccel, which is the maximum speed of pump-motor unit 217to permit the motoring mode. The fourth condition that must be met isthat the flag AccState associated with high pressure proximity switch284 must be set to the condition “accumulator not empty.” The value ofthe constants will be different depending on the specific hydraulicdrive system 102, but are set so that if the conditions are met themotoring mode may be appropriately entered.

If the conditions of flow-line 1304 are met, then hydraulic drive system102 can provide an accelerating torque. Further, if the variableSwashCmd is greater than the constant C_SwashBrakeIdleBand, then theflag AccelCmd is set to “TRUE” as shown by flow-line 1308, meaning thatthe hydraulic drive system will transition to motoring mode,Acceleration operational realm 1110. Otherwise, the flag AccelCmd is setto “FALSE” as shown by flow-line 1310, indicating that the hydraulicdrive system 102 will stay in the PumpInNeutral operational realm 1104.SwashCmd is an input resulting from a determination of a swash plateposition command, discussed with respect to Table 3 and FIG. 5. Theconstant C_SwashAccelIdleBand is discussed with respect to FIG. 9.

As control of hydraulic drive system 102 remains within operationalrealm 1104, operations 1116 and 1118 continue to be executed. Anadditional operation 1120 is also executed, and which is entitledCheckDisengageCond. An example of the operation 1120 is illustrated inFIG. 14. The flag DisengageCmd, used to exit out of state 1100, is setequal to “TRUE” if there is a specified type of fault that takes placewithin hydraulic drive system 102. Control will also exit state 1100 ifthe variable HLAOpMode, discussed above with respect to Table 3, is setto execute a “soft shutdown.” Finally, the DisengageCmd flag will alsobe set equal to “TRUE” if the speed of pump-motor unit 217 is greaterthan or equal to a disengagement speed represented by the constantC_DisengageSpeed. The value of the constant C_DisengageSpeed will dependon various conditions as well as the physical make up of the relevantportions of the hydraulic drive system 102.

Control will leave operational realm 1104 to pass into operational realm1106 to permit pumping when the flag BrakeCmd is set equal to “TRUE,” asshown by flow-line 1122. Control will return to operational realm 1104when the pumping mode is complete as shown by flow-line 1124. Theposition of the swash plate 216 is controlled to permit an exit tooperational realm 1104 either by de-stroking to neutral in a constantrate manner as discussed with respect to state 1706 or by de-stroking toneutral in a variable rate manner as discussed with respect to state1708, both of which are discussed further below.

Similarly, control will leave operational realm 1104 to pass intooperational realm 1110 to permit motoring when the flag AccelCmd is setequal to “TRUE,” as shown by flow line 1126. As shown by flow-line 1128,control will return to operational realm 1104 when the motoring mode iscomplete, and when there is no need to adjust for drift of swash-plate216 as discussed with respect to FIG. 9.

The operation 1112, entitled CheckDriftCompensationCond, is illustratedin FIG. 15. The flag DriftCompensationCond is set to “FALSE” if one ofthe following conditions is met: (i) a specified fault occurs; (ii) thehydraulic drive system 102 enters into a “soft shutdown” mode; (iii) thespeed of pump-motor unit 217 is less than equal to the constantC_SwashCalibrateMinSpeed (the minimum speed of pump-motor unit 217 atwhich calibration of the swash-plate 216 can take place); (iv) the valueof the variable SwashCmd is less than the constant C_SwashBrakeIdleBandor greater than the constant C_SwashAccelIdleBand; or (v) the speed ofpump-motor unit 217 is greater or equal to the constantC_Disengagespeed. Otherwise, if the variable PumpSpeed is greater thanthe constant C_SwashCalibrateMinSpeed, then the flagDriftCompensationCond is set to “TRUE”.

However, even when the motoring mode is complete, if there is a need toadjust for drift of the swash-plate 216 then operational realm 1108,entitled CheckNeutralDfift, is entered. As illustrated by flow-line1130, the flag DoneAccel is set to “TRUE” and the flagDriftCompensationCond is set to “TRUE”. The operational realm 1108 setsconditions and timing for executing the neutral drift compensation 900.Control of the operational realm 1108 exits when appropriate by the flagDriftCompExitCmd being set equal to “TRUE,” and then returns back tooperational realm 1104 by way of flow-line 1132, where the pump-motor130 is in neutral.

Operation 1114, entitled CheckDriftExit, is used in deciding whether toexit operational realm 1108. As illustrated in FIG. 16, an exit takesplace when one of the exemplary conditions is met. The conditionsillustrated include (i) a predefined system fault; (ii) a command toundertake a soft shut down hydraulic drive system 102; (iii) thevariable SwashCmd being either less than or greater than the indicatedconstant as discussed with respect to FIG. 5; (iv) the speed of thepump-motor 130 being less than a constant entitledC_SwashCalibrateMinSpeed (the minimum speed of pump-motor unit 217 atwhich calibration of the swash-plate 216 can take place) minus an offsetillustrated as being 300 RPM; (v) the pump speed being greater or equalto the constant C_DisengageSpeed (a disengagement speed of pump-motorunit 217); or (vi) a timer value being greater than a constantC_SwashCalibrationTotalTime (the total time permitted for swashcalibration to take place). As noted elsewhere, the constants are setdepending on hardware, operational and environmental conditions. If oneof the exemplary conditions is not met then the flag DriftCompExitCmd isset to “FALSE”

The operational realm 1106 associated with the operation of the pumpingmode, entitled Braking, is illustrated in greater detail in FIG. 17.Operational realm 1106 is entered by way of entry point 1702. Threestates, 1704, 1706, and 1708 are illustrated in FIG. 17. Controlinitially passes into state 1704, entitled Brake. When a flag ExitBrakeis set to “TRUE”, control then passes to state 1706, entitledExitBrakeAtConstRate, as shown by flow-line 1710. Otherwise, when thepressure of accumulator sensor 282 is greater than the value ofMaxAccPressToBrake (Table 3) control passes from state 1704 to state1708, entitled ExitBrakeAtVarRate, as shown by flow-line 1712. Variousoperations, 1714, 1716, 1718, 1720 and 1722 are called while inoperational realm 1106.

When entering operational realm 1106, mode valve is 232 is closed, andthe variable ExitBrake is set to the value of “0”. While in theoperational realm 1106 when the operation 1714, entitledCheckBrakeExitConditions, is being executed, the mode valve 232 is setto a closed orientation and the charge by-pass valve 263 is set to aclosed orientation by operation of solenoid 266. The variablePositiveSwashLimit is set to the value of “0”. The variablePositiveSwashLimit is used with motoring mode as opposed to pumping modeas discussed in Table 3.

The CheckBrakeExitConditions operation 1714 is illustrated in FIG. 18 inaccordance with one exemplary approach. The flag ExitBrake is set to“TRUE” if one of the following conditions is met: (i) The variableSwashCmd is greater than or equal to the value of “0” (See Table 3 andFIG. 5); (ii) a predetermined fault takes place; (iii); the hydraulicdrive system 102 is set to do a soft shutdown; (iv) the speed ofpump-motor unit 217 is less than or equal to the constantC_PumpSpeedPumpExit, which is the lowermost speed of pump-motor unit 217at which the pumping should cease; (v) the pump speed is greater than orequal to the constant of C_DisengageSpeed; or (vi) the level of lowpressure reservoir 134 drops below a predetermined level represented byC_OilLevelPumpExit as measured by sensor 286. Otherwise, the flagExitBrake is set to “FALSE,” and control remains in the brakingoperational realm 1106. The constant C_PumpSpeedPumpExit is set at 150RPM in one exemplary approach. However, more generally, the constantC_PumpSpeedPumpExit is set at a speed determined to be too low for anyeffective braking to take place, meaning that not much energy can bestored at the indicated speed; in this circumstance, controller 140 isprogrammed to initiate an exit of pumping mode.

From entry point 1702, control passes to state 1704, entitled Brake. Theflag DoneBrake is set to “FALSE,”, while the variable SwashOut is set tothe value of “0” degrees. The variable NegativeSwashLimit is set to thevalue represented by SwashBrakeLimit (Table 3). While in the Brake state1704, the operation 1718, entitled BrakeMore, and the operation 1716,entitled BrakeLess, are executed.

An example of the BrakeMore operation 1718 is illustrated in FIG. 19.Operation 1718 is called when an operator command SwashCmd requests amore negative displacement to swash-plate 216. The operation continuesif the variable SwashCmd is less than the value of the variable SwashOutas shown by flow-line 1902. This condition indicates that an operator ofvehicle 100 continues to push on the braking pedal. Therefore, thebraking command increases. Consequently, the variable SwashOut will bere-computed based on this continued braking command from the operator,but also accounting for a built-in constant rate that will alwaysoverride an operator command.

Two possible outcomes upon a brake command are therefore possible. Asshown by flow-line 1904, if the value of difference between thevariables SwashOut and SwashCmd is greater than the constantC_SwashBrakeDecrease, then the variable SwashOut is set to its previousvalue less the value of the constant. Otherwise, as shown by flow-line1906, the value of the variable SwashOut is set to the value of thevariable SwashCmd.

Accordingly, if a commanded change is greater than the built-in rate ofchange, the built-in rate of change takes precedence. In one example,the built-in rate is 500 msec for a 15 degree change in angulardisplacement of swash-plate 216. Thus, if a change of two (2) degrees iscommanded, the change cannot happen faster than 2 deg*(500 msec/15 deg)or 66.6 msec. C_SwashBrakeDecrease is set in one example at 0.15 degreesper cycle (i.e., count), where a cycle is 5 msec. Thus, only a 0.15degree of change will be allowed in 5 msec. The result is that a maximumchange from zero (0) degrees to fifteen (15) degrees cannot happen inless than 500 msec.

On the other hand, as shown with respect to the BrakeLess operation 1716in FIG. 20, this latter operation is utilized if the value of thevariable SwashCmd is greater than the value of the variable SwashOut asshown by flow-line 2002. The operation 1716 is called if an operatorcommand requests a less negative displacement of swash-plate 216. Asshown by flow-line 2004, if the difference between the value of thevariable SwashCmd and the variable SwashOut is greater than the constantC_SwashBrakeIncrease, then the value of the variable SwashOut is set tothe prior value of SwashOut plus a constant C_SwashBrakeIncrease.Finally, the variable SwashOut is set equal to the minimum value ofeither the current value of SwashOut or “0”. Otherwise, in the otherbranch of the operation 1716, as shown by flow-line 2006, the value ofthe variable SwashOut is set equal to the variable SwashCmd. Finally,the variable SwashOut is then set equal to the minimum of either thecurrent value of the variable SwashOut or “0”. The setting of thevariable to “0” ensures that the system does not go into an accelerationrealm of positive angular displacements. The constantC_SwashBrakeIncrease is set to 0.15 using the same rationale as forC_SwashBrakeDecrease, above.

Using the value of SwashOut from either operation 1716 or operation1718, SwashOut is then set in state 1704 to the maximum of either thecurrent value of SwashOut or the SwashBrakeLimit, whichever is larger(or in other words, whichever is less negative). This ensures that thecommand does not go beyond the limited command of SwashBrakeLimit, whichis the number that is limited by the speed of pump-motor unit 217. Inexample, if the speed is greater than 2000 RPM, the maximum alloweddisplacement of swash-plate 216 goes down. (See Table 3).

The value of SwashOut changes while in the Brake state 1704. Dependingon the exit conditions associated with either flow-line 1710 or 1712,control passes to different approaches for exiting braking. Followingflow-line 1710 first, control passes to ExitBrakeAtConstRate state 1706when the flag ExitBrake is set to “TRUE”. A timer starts. While thetimer is operating, the value of the variable SwashOut is set to thecurrent value of SwashOut plus the constant C_SwashBrakeIncrease. Thenthe variable SwashOut is set to the minimum of the current value ofSwashOut or “0”. Next, the value of SwashOut is set to the maximum ofthe current value of SwashOut or the value of the variableSwashBrakeLimit. After the maximum value of SwashOut is determined, thevariable NegativeSwashLimit (Table 4) is set equal to the current valueof SwashOut. Finally, operation 1722, entitled CheckBrakeDoneConstRateis executed.

In state 1706, the swash-plate 216 is commanded to gradually increasefrom some negative value towards zero displacement, but by incrementsnot larger than the constant C_SwashBrakeIncrease. Swash-plate 216 alsoneeds to be limited by zero (0) on the positive or maximum side and bySwashBrakeLimit on the negative or minimum side. That is whySwashOut=min (SwashOut, 0) and SwashOut=max (SwashOut, SwashBrakeLimit).

The execution of CheckBrakeDoneConstRate operation 1722 is illustratedin FIG. 21. If the value of SwashOut is greater than or equal to theconstant C_SwashBrakeIdleBand (reached neutral), or the time elapsed instate 1706 is greater than value of the constant C_SwashCmdBrakeLimit(see discussion with respect to FIG. 5) divided bySwashBrakeIncreaseRate, then the flag DoneBrake is set equal to “TRUE”.Otherwise, the flag for DoneBrake is set equal to “FALSE”.

Continuing to use the example of 500 msec as the maximum acceptable timeto move swash-plate 216 from a maximum angular displacement to neutralwhen the maximum angular displacement is approximately fifteen (15)degrees, the value of SwashBrakeIncreaseRate as a ratio is set to 500msec. Thus, the CheckBrakeDoneConstRate operation 1722 acts like a timeout operation.

Exemplary values of various constants follow:

SwashBrakeDecreaseRate=15/0.5; % (deg/sec), larger magnitude

SwashBrakeIncreaseRate=15/0.5; % (deg/sec), smaller magnitude

C_SwashBrakeDecrease=SwashBrakeDecreaseRate*5 msec; % (deg)

C_SwashBrakeIncrease=SwashBrakeIncreaseRate*5 msec; % (deg)

If flow-line 1712 is followed between states 1704 and 1708, then theexit of braking is at a variable rate using ExitBrakeAtVarRate state1708. The variable AccPressureLimitRatio is set equal to the differencebetween maximum pressure AccPressMax (Table 3) allowed in the highpressure accumulator 138 and the pressure AccPress measured by sensor282 divided by the difference between AccPressMax and the variableMaxAccPressToBrake (Table 3). A variable LimitRatio is set equal to thevalue of the variable AccPressureLimitRatio. A variable SwashOutTemp isset equal to the variable SwashBrakeLimit (Table 3) multiplied by thevariable LimitRatio. The value of SwashOut is then set to the maximum ofthe current value of SwashOutTemp or the value of the variable SwashCmd.Next, the value of SwashOut is set to the minimum of the current valueof SwashOut plus an offset represented by the constantC_SwashBrakeIncrease. The value of SwashOut is here in case that,instead of going toward neutral, the swash-plate 216 is commanded to goin the opposite direction. In any event, it should not go faster thanthe built-in rate, as previously discussed. A command to swash-plate 216to go in the opposite direction instead of toward neutral is likely toonly happen when the pressure goes lower instead of higher and there isa need to ensure the constant rate.

The value of SwashOut is set to the minimum of the current value of thecurrent value of SwashOut or the value “0”. This setting preventsentering the acceleration realm of positive displacement. The valueNegativeSwashLimit is set equal to the value of SwashOutTemp.

Finally, operation 1720, entitled CheckBrakeDoneVarRate, is executed.Swash-plate 216 will gradually move toward zero displacement by a factorproportional to how far the actual pressure is from the maximum allowedpressure. The pressure gradually goes more towards a maximum allowedpressure and the swash plate 216 gradually goes towards zerodisplacement. At the same time, there are protections provided toprevent an undesirable movement into positive displacement or towardsmore negative displacement if for some reason the pressure reverses.

The execution of CheckBrakeDoneVarRate operation 1720 is illustrated inFIG. 22. The flag DoneBrake is set equal to “TRUE” if the accumulatorpressure AccPress is greater than the value of the maximum acceptablepressure AccPressMax, or if the angle SwashFbk from sensor 218 and/or220 is greater or equal to than the constant C_SwashBrakeIdleBand.Otherwise, the variable DoneBrake is set to “FALSE”. Generally, brakingmay be determined to be done if the swash-plate 216 is in its neutralposition, or if the pressure of the accumulator 238 is at its maximumacceptable level.

Please note that there are symmetries between the pumping mode and theacceleration mode. For example, more generally the variableAccPressureLimitRatio for both modes can be considered as the absolutevalue of the difference between a high pressure device pressurethreshold and the measured pressure divided by the difference betweenthe a high pressure device pressure threshold and a predeterminedpressure. The high pressure device pressure threshold will either beAccPressMin or AccPressMax while the predetermined pressure will eitherbe MinAccPressToAccel or MaxAccPressToBrake.

Acceleration operational realm 1110 is shown in more detail in FIG. 23.Control enters into operational realm 1110 by way of entry point 2302.Three states, 2304, 2306, and 2308, are illustrated in FIG. 17. Controlinitially passes into state 2304, entitled Accel. When a flag ExitAccelis set to “TRUE”, control passes to state 2306, entitledExitAccelAtConstRate, as shown by flow-line 2310. Otherwise, when (i)the pressure of accumulator sensor 282 is less than or equal to greaterthan the value of MinAccPressToAccel; or (ii) the speed of pump-motorunit 217 is greater than or equal to the constant C_MaxPumpSpeedToAccel,then control passes from state 2304 to state 2308, entitledExitAccelAtVarRate, as shown by flow-line 2312.

In one exemplary illustration MinAccPressToAccel is set equal to 150Bars. This is the default value. The value, acting as a limit isconstantly being evaluated and modified by the temperature compensationheuristic 800 discussed with respect to FIGS. 7 and 8. The rationale isthe following: this value is directly related (positive 15 bar offset)to the variable AccPressMin. AccPressMin defaults to 135 Bars in theillustration because it was found to be close to the accumulatorprecharge value. If hydraulic drive system goes below this value thehigh pressure proximity switch 284 closes and the pressure in the systemdrops to close to zero.) As noted above with respect to FIG. 13, theconstant C_MaxPumpSpeedToAccel represents the maximum pump speed that isacceptable to permit the motoring mode without potentially damaging thepump-motor 130 or charge pump 204. Various operations, 2314, 2316, 2318,2320 and 2322 are called while in operational realm 1110.

In contrast to the pumping mode, when entering operational realm 1110, asignal is sent to open mode valve 232 using solenoid 238 while there isno signal to charge by-pass valve 263, permitting it to become open.While in operational realm 1110, operation 2314, entitledCheckAccelExitCond, is executed. Also while in the operational mode1110, the signal to solenoid 238 continues to be “ON,” while the signalto charge by-pass valve solenoid 266 continues to be “OFF.” The variableNegativeSwashLimit (Table 4) is set equal to “0,” because the variablerelates to the pumping mode and not to the motoring mode.

CheckAccelExitCond operation 2314 is illustrated in FIG. 24. The flagExitAccel is set equal to “TRUE” if one of the following conditions ismet: (i) the variable SwashCmd is less than or equal to “0”; (ii) thereis a predefined fault; (iii) the controller is set to do a “softshutdown;” or (iv) the high pressure proximity switch 284 changes stateto “accumulator empty.” The latter condition will result in the need forinvoking the precharge logic as discussed above. If none of theconditions (i) through (iv) are met, then the flag ExitAccel is setequal to “FALSE”.

As noted above, when control passes to operational realm 1110, controlenters at entry point 2302 and passes into Accel state 2304. The flagDoneAccel is set equal to “FALSE”. The variable PositiveSwashLimit(Table 4) is set equal to the value of the variable SwashAccelLimit(Table 3), and the variable SwashOut (Table 3) is set equal to “0”degrees. While staying within operational realm 2304, operation 2316,entitled AccelMore, and operation 2318, entitled AccelLess are executed.Finally, the value of SwashOut is set as (i) the minimum of the currentvalue of SwashOut after the operations are called, or (ii) the value ofSwashAccelLimit.

The AccelMore operation 2316 is illustrated in more detail in FIG. 25.Operation 2316 is called when an operator command requests a morepositive displacement to swash-plate 216. In order for the operation2316 to continue executing, the value of SwashCmd must be greater thanthe current value of SwashOut as shown by flow-line 2502. If the valueof SwashCmd must be greater than the current value of SwashOut, then oneof two values of SwashOut are possible. As shown by flow-line 2504, ifthe value of SwashCmd is greater than the current value of SwashOut plusthe value of a constant C_SwashAccelIncrease, then the value of SwashOutis first set equal to the current value of SwashOut plus the amount ofthe constant C_SwashAccelIncrease.

Operation 2316 generally mirrors the one discussed above with respect toC_SwashBrakeIncrease in operation 1716. The purpose of the operation2316 is to prevent an increase in angular displacement of swash-plate216 of more than an equivalent of fifteen degrees in 500 msec using oneset of exemplary values. A constant, built-in rate overrides anyoperator command seeking movement beyond the maximum acceptable built-inrate to avoid abrupt changes in acceleration.

Exemplary values of various constants follow:

% Motor Swash Constants (Motoring is Positive)

SwashAccelDecreaseRate=15/0.5; % (deg/sec)

SwashAccelIncreaseRate=15/0.5; % (deg/sec)

C_SwashAccelDecrease=SwashAccelDecreaseRate*5 msec; % (deg)

C_SwashAccelIncrease=SwashAccelIncreaseRate*5 msec; % (deg)

Finally, SwashOut is set to the minimum of the current value of SwashOutor the value of SwashAccelLimit. Otherwise as shown by flow-line 2506,the value of SwashOut is set to the value of SwashCmd, and then thevalue of SwashOut is set to the minimum of either the current value ofSwashOut or the value of SwashAccelLimit. Thus, the swash plate 216 iscommanded to a more positive displacement (i.e., to accelerate more).First, there is a check to see if the increase in the operator commandis greater than the built-in rate C_SwashAccelIncrease. If there is,then the operator command is overridden by the built-in rate. Otherwise,the operator command is applied because it is not greater than themaximum built-in rate, and therefore the operator command is acceptable.Further, the maximum command is generally limited to less than the valueof SwashAccelLimit.

The AccelLess Operation 2318 is shown in more detail in FIG. 26. It iscalled when an operator command requests a less positive angulardisplacement to swash-plate 216. In order for the operation 2318 tocontinue, the value of the variable SwashCmd must be less than the valueof the variable SwashOut as shown by flow-line 2602. If it is, then oneof two possible flow-lines may be followed. As illustrated by flow-line2604, if the value of SwashCmd is less than the difference between thevalue of SwashOut and the constant C_SwashAccelDecrease, then the valueof SwashOut is set to the difference between the current value ofSwashOut and the constant C_SwashAccelDecrease. Finally, the value ofSwashOut is set to the maximum of the current value of SwashOut or “0”.If the conditions associated with flow-line 2604 are not met, then, asshown by flow-line 2606, the value of SwashOut is first set equal to thevalue of SwashCmd. Then the value of SwashOut is set equal to themaximum of the current value of SwashOut or “0”.

Swash-plate 216 in the foregoing scenario is commanded to a lesspositive displacement (i.e., to accelerate less). Controller 140 checksto see if the decrease in operator command is greater than the built-inrate C_SwashAccelDecrease, and if so, the operator command is overriddenby the built-in-rate. Otherwise, the command is applied because it isnot greater than the built-in rate and is therefore acceptable.Moreover, checks are placed to limit the operator command to no lessthan “0”.

Control passes from Accel state 2304 to ExitAccelAtConstantRate 2306 byway of flow-line 2310 when the condition ExitAccel is set to “<TRUE”.When in state 2306, the flag DriftCompensationCond is set equal to“FALSE”, A timer is started. While the timer is running, the value ofSwashOut is set equal to difference between the current value ofSwashOut and the constant C_SwashAccelDecrease (no change beingpermitted that is greater than the built-in rate). Next, the value ofSwashOut is set to the maximum of either current value of SwashOut or“0”. This setting is a guard to make sure the system does not decreasebelow “0”. Next, the value of SwashOut is set to the minimum of thecurrent value of SwashOut or the value of the variable SwashAccelLimit.This is a guard to a maximum SwashAccelLimit. Once the minimum value ofSwashOut has been set the variable PositiveSwashLimit is set equal tothe current value of SwashOut. Finally, the CheckDriftCompensationCondoperation 1112 is executed, followed by the operation 2320, entitledCheckAccelDoneConstRate.

The CheckAccelDoneConstRate operation is discussed in more detail inFIG. 27. In order for the flag DoneAccel to be set equal to “TRUE,” oneof the following conditions must be met: (i) the value of SwashOut mustmeet be less than the constant C_SwashAccelIdleBand; or (ii) the timeassociated with the timer for state 2306 is greater than the value ofC_SwashCmdAccelLimit (FIG. 5) divided by the value of the variableSwashAccelDecreaseRate. Otherwise, the flag DoneAccel is set equal to“FALSE.”

An alternative way to exit Accel state 2304 is to go toExitAccelAtVariableRate state 2308 by way of flow-line 2312. One of twoconditions associated with flow-line 2312 must be met. The accumulatorpress AccPress associated with sensor 282 must be less then or equal tothe minimum pressure to accelerate MinAccPressToAccel. Alternatively,the speed of motor-pump 217 is greater than or equal to the constantC_MaxPumpSpeedToAccel.

When in state 2308, the value of the variable AccPressressureLimitRatiois equal to the difference between the accumulator pressure AccPress andthe value of AccPressMin (Table 4) divided by the difference between thevalue of MinAccPresstoAccel and the value of AccPressMin. The variableSpeedLimitRatio is set equal to the difference between the constantC_SpeedMaxAccelExit and the current speed of pump-motor unit 217 dividedby the difference between the constant C_SpeedMaxAccelExit and theconstant C_MaxPumpSpeedToAccel. The constant C_SpeedMaxAccelExit is setin one exemplary approach at 2500 RPM. More generally, however, thevalue is set to a speed determined to be too high for the pump 217 tospin at displacement. Thus, the foregoing limitation is an operation ofa hardware limitation. A variable SwashOutTemp is set equal to the valueof SwashAccelLimit times the value of SpeedLimitRatio. Next the variableSwashOut is set equal to the minimum of the current value ofSwashOutTemp or the current value of SwashCmd (to impose a change nohigher than the variable limit).

Next, the value of SwashOut is set equal to the maximum of thedifference between the current value of SwashOut and the constantC_SwashAccelDecrease, or the current value of SwashOut. This setting isdone in case either the pressure or the speed begin to change in anopposite direction. Thus, this setting of SwashOut ensures a gradualchange; in this case, the constant rate is used.

Finally, the value of SwashOut is set to the maximum of the currentvalue of SwashOut or the value “0” to guard against no less than zero(“0”) displacement. The variable PositiveSwashLimit is set equal tovalue of SwashOutTemp. Next, operation 2322, entitledCheckAccelDoneVarRate, is executed.

CheckAccelDoneVarRate operation 2322 is illustrated in FIG. 28. The flagDoneAccel is set equal to “TRUE” if one of following three exemplaryconditions are satisfied: (i) the accumulator pressure AccPress is lessthan or equal to the value of AccPressMin; (ii) the speed of pump-motor217 is greater than or equal to the constant C_SpeedMaxAccelExit; or(iii) the angular displacement SwashFbk of swash-plate 216 is less thanor equal to the constant C_SwashAccelIdleBand. Otherwise, the flagDoneAccel is set equal to “FALSE”.

Aggressive Clutching

Another mechanism to improve the efficient use of hydraulic drive system102 is the use of aggressive clutching. The mechanism is used primarilywhen clutch 208 is a progressive wet disk friction clutch such as isknown, A simplified portion of an exemplary hydraulic circuit 2900 for aclutch system for use with an aggressive clutch mechanism is shown inFIG. 29. Circuit 2900 includes clutch 208, shown as an actuator piston.Associated with the actuator piston 208, however, is clutch packlubrication 2902 and angular contact bearing lubrication 2904. Circuit2900 includes a high pressure accumulator 2906 and a hydraulic fluidreservoir, called oil reservoir 2908. Hydraulic fluid flows fromreservoir 2908 to high pressure accumulator by way of an electric motor2910 rotating a gerotor pump 2912 from a low pressure side conduit 2914to a high pressure side conduit 2916 through a filter 2918 and a one-waycheck valve 2920.

When clutch 208 is applied, solenoid 290 causes selective and controlledapplication of proportional clutch valve 292, receiving high pressurehydraulic fluid from accumulator 2906 by way of high pressure conduit2916. The strength of the signal received by solenoid 290 controls thelevel of hydraulic force applied by valve 292 using the available fluid,thereby controlling the amount of force applied by clutch 208 asrepresented by the illustrative actuator piston in FIG. 29. Fluidflowing through proportional clutch valve 292 follows fluid conduit 2922to clutch 208. Disposed within high pressure conduit 2916, however,between accumulator 2906 and proportional clutch valve 292 is atransducer 2924, providing an alternate pathway conduit 2926 withincircuit 2900. Conduit 2926 is disposed between transducer 2924 and bothangular contact bearing lubrication 2904 and clutch pack lubrication2902. A relief valve 2928 is disposed within conduit 2926 downstream oftransducer 2924, but upstream of the lubrication mechanisms 2902 and2904. Finally, inlet pressure for the clutch can be measured usingsensor 2928.

As illustrated in general terms in FIGS. 1 and 2, when a clutch 208associated with vehicle drive-line 116 is used to interconnectintermediate shaft 202 to gearing set 210 and then to shaft 206 therebyto convert mechanical energy to hydraulic energy, there is a potentialproblem of parasitic drag. Thus, it is desirable to have hydraulic drivesystem 102 disengaged from the rest of vehicle drive system 110 until itis needed. Yet when system 102 needs to engage, it is also desirable tohave the clutch 208 apply as quickly as possible, so that the maximumamount of power may be turned into hydraulic energy, and alsotransparently to a vehicle 100 operator; that is, without causingundesirable torque spikes within drive-line 116.

A subsystem 3000 of hydraulic drive system 102 is illustrated in FIG.30. The subsystem 3000 is entered at entry point 3002 when drive system102 is disposed between a motoring mode and a pumping mode. Twooperational realms are shown, operational realm 3004, entitled Wait, andoperational realm 3006, entitled ClutchEngage. Wait operational realm3004 is discussed further below with respect to FIG. 31, whileClutchEngage operational realm 3006 is discussed below with respect toFIGS. 32 through 35.

Control leaves Wait operational realm 3004 to go to ClutchEngageoperational realm 3006 by way of flow-line 3008 when five exemplaryconditions are all met. In some systems more or fewer conditions may berequired. First, the variable HLAOpMode must be set to a flag vsc_normalindicating that the hydraulic drive system is operating normally and maybe permitted to move between a pumping mode and a motoring mode. Second,there must be no faults that keep the system from operating correctly.For example, flow-line 3008 is traversed when FaultLevel is not equal to“1” and not equal to “2”. As noted in Table 3, above, one type of faultmay be a hardware fault, while another type of fault may be related tologic. Third, the inlet pressure associated with clutch 208 as measuredby sensor 2928 must be greater than a minimum thresholdMinEngageInletPress, which is a constant. The value of the constant willvary from system to system, but should be generally adequate to permitfull application of clutch 208 to permit either a charge operation or adischarge operation. The fourth condition that needs to be met is thatthe speed of rotation of the shafts OutputShaftSpeed associated withdrive-line 116, including intermediate shaft 202, and as provided by theCAN associated with vehicle 100 (See Table 3), is less than a constantC_DisengageSpeed, which is maximum disengagement speed. Finally, thefifth condition that also must be met along with conditions one throughfour actually must include at least only one of the following threeconditions: (i) the variable TransShaftSpeed must be less than aconstant MinDisengageSpeed; (ii) the variable SwashCmd must be less thanor equal to the constant C_SwashBrakeIdleBand or (iii) the variableSwashCmd must be greater than or equal to the constantC_SwashAccelIdleBand. The variable SwashCmd is discussed in Table 3 andwith respect to FIG. 5. The constants C_SwashBrakeIdleBand andC_SwashAccelIdleBand are discussed in more detail with respect to theconditions of Flow-Line 908. Regarding the constant MinDisengageSpeed,it is used to disengage clutch 208 if pump-motor 130 has been rotatingat a pump speed greater than the value of the constant for too longwhile being held at zero displacement (in neutral), which is a harmfulcondition for pump-motor 130. If such a condition takes place,FaultLevel is set to a value of “1”, which is a condition to go fromEngaged state 1100 to a disengaged state.

Once control has passed from operational realm 3004 to operational realm3006, there are three ways to leave operational realm 3006. First, ifthe clutch 208 correctly engages, then sub-system 3000 is exited by wayof flow-line 3010. Alternatively, if a time for clutch engagement isgreater than variable ClutchTime5_6, discussed in more detail below,including with respect to FIG. 35, then, as shown by flow-line 3012, theflag FailedEngagementCount (Table 4) is set to “TRUE,” and controlreturns back to operational realm 3004. Finally, control also passesfrom ClutchEngage operational realm 3006 to Wait operational realm 3004if one of the following conditions are satisfied. First, a fault isdetected as shown by FaultLevel being equal to either “1” or “2” in theillustrated flow-line 3014. Second, the variable HLAOpMode is not equalto the flag for normal operation vsc_normal. Finally, the third possiblecondition for flow-line 3014 is that the output shaft speed fordrive-line system 110 is greater than the constant C_DisengageSpeed plusa predetermined offset, which is illustrated in this example as fifty(50) RPM.

The Wait operational realm 3002 is illustrated in greater detail in FIG.31. Basically, within operational realm 3002, if certain conditions aremet, a command is applied to the clutch 208 in the form of a current sothat the clutch is almost ready to apply, i.e., is very close to athreshold to apply. Because a very little bit more current is requiredto apply the clutch, meaning the clutch may be engaged very quickly.Whether the current is applied is highly dependent on the speed of theshafts of drive-line system 110, including intermediate shaft 202.

Operational realm 3002 is entered by way of entry point 3102, wherecontrol passes to state 3104, entitled ClutchDisengaged. A command byway of TransCaseCmd has been sent to solenoid 290 to make sure thatclutch 208 is disengaged. The signal MainBypassCmd to bypass valve 246,the signal IsolationCmd to isolation valve 242, and the signal ModeCmdto mode valve 232 have all been set to condition “OFF,” with theconsequences for each of the valves as discussed, for example, in Table4. Finally, the flag associated with variable SwashEnable has been setto “FALSE,” as discussed with respect to Table 4.

Control passes from state 3104 to state 3106, entitled WaitDisengaged,by way of flow-line 3108, when the conditions associated with theflow-line 3108 are met. These conditions are that first, output shaftspeed OutputShaftSpeed must be less than the constant C_DisengageSpeedplus an offset, which is illustrated as 200 RPM. Second, the outputshaft speed must be greater than the constant MinDisengageSpeed. Third,there cannot be a system fault FaultLevel.

When in state 3106, a timer is started. The purpose of starting thistimer is to make sure that all the conditions necessary for the clutch208 to engage are maintained. Control passes to state 3110, entitledClutchDisengagedAggressive, by way of flow-line 3112, when the timeassociated with the timer of state 3106 is greater than a value set asDissAggressiveTime and the operational mode of hydraulic drive systemHLAOpMode is normal.

In state 3110 a flag is set with respect to the variable TransCaseCmd tosend a signal to clutch 208 by way of solenoid 290 to clutch valve 292so that clutch 208 is just about ready to engage. In one illustration,TransCaseCmdHold=0.6 A. This current called the “hold” current is lowenough to prevent an engagement. When an engagement is commanded, and ahigher current is applied, it takes less time to get to that current ifthe hold current is already flowing through the coil of solenoid 292. Asis known, when current is applied to a solenoid, the solenoid'sinductance causes the current to rise to the desired value after acertain delay proportional to the inductance and inversely proportionalto the current.

Operational realm 3004 stays in state 3110 unless the conditionsassociated with flow-line 3008 or flow-line 3114 are met. The conditionsassociated with flow-line 3114 are (i) either the hydraulic drive system102 no longer is operating normally; or (ii) the output shaft speedOutputShaftSpeed is greater than the constant C_DisengageSpeed plus anoffset, illustrated as 250 RPM for the flow-line. If either condition ismet, control returns back to state 3104, and the clutch is againdisengaged along with the change of conditions of the other variables asdiscussed above. Operational realm 3004 moves between the states 3104,3106 and 3110 until operational realm 3004 is exited as discussed abovewith respect to FIG. 30. Most likely, control will be within state 3110when the exiting happens.

ClutchEngage operational realm 3006 is illustrated in more detail inFIG. 32. When the realm is entered at entry point 3202 the variablePumpSpeedInst is set equal to the pump speed PumpSpeed of motor-pump130. The bypass valve 246 is set to the condition MainBypassCmd “ON,”the isolation valve 242 is set to the condition IsolationCmd “ON,” andthe flag associated with variable SwashEnable has been set to “TRUE,” asdiscussed with respect to Table 4. Finally, the variable SwashOut1 hasbeen set equal to “0.” This command indicates that the swash-plate 216is commanded to be in the neutral position. As noted elsewhere, however,if the precharge heuristic 600 is active, the precharge heuristic takesprecedence over the SwashOut1 command.

As discussed in more detail, the signals sent to solenoid 290 of clutchvalve 292 to engage clutch 208 will vary at different times. In essence,in the illustrated system 102, a current profile is created for eachparticular hardware arrangement to account for different types ofconditions affecting clutch application. While high efficiency isdesired, it is also important to control the application of clutch 208so that a user of hydraulic drive system 102 is not subjected toundesirable impressions with respect to hydraulic drive system. Further,it is desirable to minimize undue wear to hydraulic clutch 208 throughoverly aggressive clutch application by way of hydraulic circuit 2900.The illustrated arrangement is merely exemplary and to give one approachto address the issue of finding a balance between short-termefficiencies as compared to long-term performance or perception. When ahydraulic clutch 208 is used, it is possible to apply engage the clutchat higher speeds (i.e., when a pumping mode is requested, vehicle 100 ismoving at some velocity) while a simpler mechanical dog-type clutch canbe engaged at a vehicle velocity of essentially zero. In the lattersituation, when a vehicle operator is ready to request braking, clutch208 has been engaged for some period of time prior to the request.

After entering ClutchEngage operational realm 3006 by way of entry point3202, control moves to state 3204, entitled Clamping. The operationClutchTimeClamping 3206 is performed, and the results from the operation3206 are used to set the signal sent by the variable TransCaseCmd tocontrol the variable application of clutch 208.

In general, a clamping current is a current higher than what is neededto engage the clutch 208. It is applied for a short period of time(ClutchTimeClamping) at the beginning of the engagement sequence to“jump start” the engagement. After the clamping discussed below takesplace subsystem 3000 reverts to a smaller current and the profiledescribed in engaging state 3208 is implemented.

Operation ClutchTimeClampingCalc 3206 is illustrated in more detail inFIG. 33. The operation 3206 is entered by way of entry point 3302 and isexited by way of points 3304, 3306, 3308 or 3310 once the conditionsassociated with the indicated exit point 3304, 3306, 3308 or 3310 aremet. In general, the time for clutch clamping varies as operation of thetemperature of the hydraulic fluid measured by temperature sensor 288 inlow pressure reservoir 134. Merely by way of illustration, a firstclutching time ClutchTimeClamping1 is set if the oil temperature OilTempassociated with sensor 288 is less than a first predetermined oiltemperature OilTemp1. Otherwise, if the oil temperature is less than asecond predetermined oil temperature OilTemp2, then the variableClutchTimeClamping is set to a second predetermined value ofClutchTimeClamping2. Finally, and merely as an example, if the oiltemperature is less than a third oil temperature, then the variableClutchTimeClamping is set to a third value. Fewer or additionalacceptable conditions representing the relationship between oiltemperature and time can be set. However, if none of the conditions aremet, then a default clamping time is set, which is shown in Figure O asbeing equal to the predetermined value ClutchTimeClampingP3.

In general, for hydraulic drive system 102 it has been determined thatit should take less time to clamp clutch 208 as temperature increases.Advantageously, therefore, it is possible to reduce overall engagementtime to promote efficiency of hydraulic drive system 102. As merely oneexample, the variables have been set where each increase in the clutchclamping time variable results in a reduction of time of one count,where one count represents 5 msec. The temperature is based onobservable thresholds that are associated with the hardware, operationaland environmental conditions, but the variable associated with OilTempgoes up as temperature increases. More specifically, in one illustrationthe variables have been set as follows:

OilTempP1=32° C.

OilTempP2=48° C.

OilTempP3=60° C.

ClutchTimeClampingP1=13 counts, each count is 5 msec−>13*5=65 msec.

ClutchTimeClampingP2=12 counts, each count is 5 msec−>12*5=60 msec.

ClutchTimeClampingP3=11 counts, each count is 5 msec−>11*5=55 msec.

Once the clutch command TransCaseCmd has been sent in state 3204, atimer is then set. As shown by flow-line 3210, control passes from state3204 to state 3208, entitled Engaging, when the time associated with thetimer of state 3204 is greater than time entitled ClutchTimeClamping,set by operation ClutchTimeClampingCalc 3206, or the speed PumpSpeed ofmotor-pump 130 is greater than the variable previously set asPumpSpeedInst plus an offset, shown as 25 RPM in the presentillustration. The offset indicates that the pump shaft 206 is startingto rotate.

Engaging state 3208 is discussed in more detail with respect to FIG. 34and FIG. 35. However, operational realm 3006 is shown exiting from state3208 by way of lines 3010, 3012, or 3014 as discussed with respect toFIG. 30 above.

Engaging state 3208 is entered by way of flow-line 3210 in FIG. 34.Within engaging state 3208 the operation ClutchProfileCalc 3404 isperformed. As illustrated in FIG. 35, if the output shaft speedOutputShaftSpeed is less than the constant SpeedEngP1 as shown byflow-line 3502, then various clutch command signals and correspondingclutch times are set to an indicated value. In one illustrated approach,SpeedEngP1 is equal to 750 RPM. Otherwise, different values are set asshown by flow line 3504. In one embodiment, the same parameters are usedirrespective of the speed of the engine. However, in other embodimentsthere may be a difference since it is anticipated that at lower enginespeeds it will take less force to engage.

In general the variables are set using a torque sensor and by analyzingfeedback to determine how smooth the engagement of clutch 208 is whileminimizing time. Thus an appropriate balance is reached betweenefficiency and perceived performance. More specifically, in one examplethe variables have been set as follows:

If TransShaftSpeed<750 rpm Then

TransCaseCmd_1_P1=0.73 A (Amps);

TransCaseCmd_2_P1=0.74 A;

TransCaseCmd_3_P1=0.75 A;

TransCaseCmd_4_P1=0.76 A;

TransCaseCmd_5_P1=0.77 A;

ClutchTime1_2P1=30 counts, each is 5 msec−>30*5=150 msec

ClutchTime2_3P1=20 counts, each is 5 msec−>20*5=100 msec

ClutchTime3_4P1=20 counts, each is 5 msec−>20*5=100 msec

ClutchTime4_5P1=10 counts, each is 5 msec−>10*5=50 msec

Else

TransCaseCmd_1_P2=0.73 A;

TransCaseCmd_2_P2=0.74 A;

TransCaseCmd_3_P2=0.75 A;

TransCaseCmd_4_P2=0.76 A;

TransCaseCmd_5_P2=0.77 A;

ClutchTime1_2P2=30 counts, each is 5 msec−>30*5=150 msec

ClutchTime2_3P2=20 counts, each is 5 msec−>20*5=100 msec

ClutchTime3_4P2=20 counts, each is 5 msec−>20*5=100 msec

ClutchTime4_5P2=10 counts, each is 5 msec−>10*5=50 msec

Once the desired values in current for clutch engagement command signalsand clutch engagement times in seconds have been determined using theoperation ClutchProfileCalc, state 3208 generally applies differentcurrents to solenoid 290 for different periods of time until fullengagement of clutch 208 takes place.

More generally, the currents correspond to a signal. As illustrated inmore detail in the paragraphs as follows a plurality of signals isapplied for a plurality of preset times until clutch 208 engages.

Box 3406 is entitled SpeedMatch1. The clutch command TransCaseCmd is setto the variable TransCaseCmd_1 from the operation ClutchProfileCalc anda timer is started. TransCaseCmd_1 may be considered a first engagingsignal. As shown by flow-line 3408, if one of three conditions is met,then control passes to box 3410. The first condition is that the timeassociated with the timer is greater than the variable ClutchTime1_2 setby the operation. The ClutchTime1_2 may be considered a first presettime. The second possible condition is that the pump speed is greaterthan the variable PumpSpeedInst plus an offset, shown as 25 RPM in theexample. The third possible condition is that the absolute value ofoutput shaft speed minus the speed of pump-motor 130 is less than apredetermined engaged speed error, entitled EngageSpeedError. Forconvenience, this third condition is referred to as the speed errorcondition.

The variable EngageSpeedError is the difference between the two sides ofthe clutch 208, namely the speeds of intermediate shaft 202 andpump-motor shaft 206. In one example, if the difference is less than apredetermined level (e.g., 50 RPM), then it is considered that the twosides of the clutch 208 are engaged. Thus, some slippage of the clutchis permitted, but the amount of slippage is controlled.

In box 3410, entitled SpeedMatch2, the clutch command signal is set toTransCaseCmd_2, which may be considered a second engaging signal. Avariable delta is set equal to the difference betweenTransCaseCmd_(—)3−TransCaseCmd_2 divided by the value ClutchTime2_3,which may be considered a second preset time, all determined withinoperation 3404. A timer is set to run while the clutch command signal isset to the variable delta. In effect, using the variable delta, thecurrent is increased from an initial value TransCaseCmd_2 to a currentvalue TransCaseCmd_3 over the duration given by ClutchTime2_3. Ofcourse, in some systems it may be desirable for the current to stay thesame or to possibly reduce the current. Nevertheless, since the goal isto engage clutch 208, increasing current over time has been found to beadvantageous in promoting efficiency. The same is true for boxes 3414,3418, and 3426. Control will move to box 3414 by way of flow-line 3412if the timer is greater than or equal to the variable set by operation3404 of ClutchTime2_3, or if the speed error condition is met, whichmeans that clutch engagement is complete. In box 3414, entitledSpeedMatch3, the clutch command signal is set to TransCaseCmd_3. Thevariable delta is set to the difference between TransCaseCmd_4 andTransCaseCmd_3 divided by the time ClutchTime3_4. A timer is set to runwhile the clutch command signal is set to the variable delta. Controlwill move to box 3418 by way of flow-line 3416 if the timer is greateror equal to the time ClutchTime3_4 or if the speed error condition ismet, which means that clutch engagement is complete.

In box 3418, entitled SpeedMatch4, the clutch command signal is set toTransCaseCmd_4. The variable delta is set to the difference betweenTransCaseCmd_5, and TransCaseCmd_4 divided by the time ClutchTime4_5. Atimer is set to run while the clutch command signal is set to thevariable delta. Control will move to box 3422 by way of flow-line 3420if the timer is greater or equal to the time ClutchTime4_5 or if thespeed error condition is met, which indicates that the clutch engagementis complete.

In box 3422, entitled SpeedMatch5, the clutch command signal is set tothe variable TransCaseCmd_5. A timer is set and the same value is of theclutch command signal is maintained while the timer runs. There are twopossible flow-lines from SpeedMatch5 box 3422. A first flow-line P-24 isfollowed if the timer is greater than the value set for the clutch timeto engage ClutchTimeEngage. If the condition is satisfied then in box3426, entitled SpeedMatch6, a final attempt to engage the clutch 208 isattempted. The clutch command signal TransCaseCmd is set equal to thevalue associated with TransCaseCmd_5. The variable delta is set equal tothe difference between TransCaseCmd_6 and TransCaseCmd_5 divided by theclutch time value of ClutchTime5_6. A timer is set to run while theclutch command signal is set to the variable delta. If the conditiondiscussed with respect to flow-line 3012 is met, then engaging state3208 is exited as shown by the flow-Line 3012.

Thus, if the hydraulic drive system 102 is in any of the SpeedMatchstates (1 through 6) and the speed condition error is satisfied or setto “TRUE,” then the clutch 208 is engaged and there is no need to waitfor the various additional times. Thus, engaging state 3208 will runvery quickly until engagement is complete.

Unless engaging state 3208 is exited by way of line 3012, once theclutch 208 is engaged using one of boxes 3406, 3410, 3414, 3418, 3422 or3426, control leaves state 3208 using flow-line 3428. Once theconditions associated with one of the boxes is met, the control fallsthrough later numbered boxes to exit flow-line 3428.

CONCLUSION

With regard to the processes, systems, methods, heuristics, etc.described herein, it should be understood that although the steps ofsuch processes, etc. have been described as occurring according to acertain ordered sequence, such processes could be practiced with thedescribed steps performed in an order other than the order describedherein. It further should be understood that certain steps could beperformed simultaneously, that other steps could be added, or thatcertain steps described herein could be omitted. In other words, thedescriptions of processes herein are provided for the purpose ofillustrating certain embodiments, and should in no way be construed soas to limit the claimed invention.

Accordingly, it is to be understood that the above description isintended to be illustrative and not restrictive. Many embodiments andapplications other than the examples provided would be apparent to thoseof skill in the art upon reading the above description. The scope of theinvention should be determined, not with reference to the abovedescription, but should instead be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. It is anticipated and intended that futuredevelopments will occur in the arts discussed herein, and that thedisclosed systems and methods will be incorporated into such futureembodiments. In sum, it should be understood that the invention iscapable of modification and variation and is limited only by thefollowing claims.

All terms used in the claims are intended to be given their broadestreasonable constructions and their ordinary meanings as understood bythose skilled in the art unless an explicit indication to the contraryin made herein. In particular, use of the singular articles such as “a,”“the,” “said,” etc. should be read to recite one or more of theindicated elements unless a claim recites an explicit limitation to thecontrary.

1. A hydraulic drive system for storing and releasing hydraulic fluidcomprising: a high pressure storage device; a low pressure storagedevice; a pump-motor operating at a range of pump-motor speeds forconverting between hydraulic energy and mechanical energy, saidpump-motor disposed between said high pressure storage device and saidlow pressure storage device; a switch for controlling flow of saidhydraulic fluid from said high pressure storage device, said switch in afirst state for enabling release of said hydraulic fluid from said highpressure storage device when a pressure within said high pressurestorage device is above a predefined threshold, and said switch in asecond state for substantially blocking release of said hydraulic fluidfrom said high pressure storage device when said pressure within saidhigh pressure storage device is below said predefined threshold, saidpredefined threshold being adjusted as said switch changes from saidfirst state to said second state.
 2. A hydraulic drive system as recitedin claim 1, wherein a first pressure reading is assigned as saidpredefined threshold.
 3. A hydraulic drive system as recited in claim 1,wherein when said switch changes from said first state to said secondstate, a second pressure reading is assigned as said predefinedthreshold, said second pressure reading being equal to said firstpressure reading plus an offset value.
 4. A hydraulic drive system asrecited in claim 3, wherein when said switch appears to change betweensaid first state and said second state, a timer is invoked and saidstate of said switch is confirmed after said timer runs to minimize apotential error.
 5. A hydraulic drive system as recited in claim 4,where said potential error is a false signal.
 6. A hydraulic drivesystem as recited in claim 1, further comprising a motoring modeincluding a request that said hydraulic fluid be released from said highpressure storage device, said switch arranged in said second state forsubstantially blocking release of said hydraulic fluid from said highpressure storage device when operating in said motoring mode and saidpressure within said high pressure storage device is below saidpredefined threshold.
 7. A hydraulic drive system for storing andreleasing hydraulic fluid comprising: a high pressure storage device; alow pressure storage device; a pump-motor operating at a range ofpump-motor speeds for converting between hydraulic energy and mechanicalenergy, said pump-motor disposed between said high pressure storagedevice and said low pressure storage device; a switch associated withsaid high pressure storage device, said switch in a first state when apressure within said high pressure storage device is above a predefinedthreshold and said switch in a second state when said pressure withinsaid high pressure storage device is below said predefined threshold,said predefined threshold being adjusted as said switch changes fromsaid first state to said second state, and wherein said predefinedthreshold changes states as temperature changes within said system.
 8. Ahydraulic drive system for storing and releasing hydraulic fluidcomprising: a high pressure storage device; a low pressure storagedevice; a pump-motor operating at a range of pump-motor speeds forconverting between hydraulic energy and mechanical energy, saidpump-motor disposed between said high pressure storage device and saidlow pressure storage device; a motoring mode where hydraulic energyreleased from said high pressure storage device is converted tomechanical energy using said pump-motor; a pumping mode where mechanicalenergy is converted into hydraulic energy and stored in said highpressure storage device; a neutral mode where hydraulic energy isneither stored nor released from said high pressure storage device; aswitch for controlling flow of said hydraulic fluid from said highpressure storage device, said switch in a first state for enablingrelease of said hydraulic fluid from said high pressure storage devicewhen a pressure within said high pressure storage device is above apredefined threshold, and said switch in a second state forsubstantially blocking release of said hydraulic fluid from said highpressure storage device when said pressure within said high pressurestorage device is below said predefined threshold, said predefinedthreshold being adjusted as said switch changes from said first state tosaid second state, wherein said predefined threshold changes states inresponse to temperature changes within said system; and wherein whensaid switch changes state from said first state to said second state, asecond pressure reading is assigned as said predefined threshold, saidsecond pressure reading being equal to said first pressure reading plusan offset value.
 9. A hydraulic drive system as recited in claim 8,wherein said offset value is a constant.
 10. A hydraulic drive system asrecited in claim 9, wherein when said switch appears to change betweensaid first state and said second state, a timer is invoked and saidstate of said switch is confirmed after said timer runs to minimize apotential false signal.
 11. A hydraulic drive system as recited in claim10, wherein said first pressure reading is established for an ambienttemperature using a lookup table, a temperature sensor providing atemperature for said lookup table.
 12. A hydraulic drive system asrecited in claim 8, wherein said switch is arranged in said second statefor substantially blocking release of said hydraulic fluid from saidhigh pressure storage device when operating in said motoring mode andsaid pressure within said high pressure storage device is below saidpredefined threshold.
 13. A method associated with a hydraulic drivesystem having a high pressure storage device and a low pressure storagedevice, a motor for converting between hydraulic energy and mechanicalenergy, the motor disposed between the high pressure storage device andthe lower pressure storage device, and comprising the steps of:providing a measured pressure of the high pressure storage device; aswitch for controlling a flow of hydraulic fluid from said high pressurestorage device, said switch changing from a first state and a secondstate when said measured pressure is below a predefined threshold, saidfirst state enabling release of said hydraulic fluid from said highpressure storage device and said second state substantially blockingrelease of said hydraulic fluid from said high pressure storage device;and adjusting said predefined threshold when said changing step takesplace.
 14. A method as recited in claim 13, wherein said adjusting stepcomprises the step of assigning a second pressure reading as saidpredefined threshold, said second pressure reading being equal to saidmeasured pressure plus an offset value.
 15. A method as recited in claim14, wherein said changing step comprises the step of invoking a timerwhen said switch appears to be changing between said first state andsaid second state, and confirming said state of said switch afterrunning said timer, thereby minimizing a potential error.
 16. A methodas recited in claim 13, assigning a first pressure reading as saidpredefined threshold prior to an initial changing step, and establishingsaid first pressure reading using an ambient temperature and a lookuptable.
 17. A method as recited in claim 13, further comprising the stepsof: operating said hydraulic drive system in a motoring mode thatincludes a request that said hydraulic fluid be released from said highpressure storage device; and arranging said switch in said second statefor substantially blocking release of said hydraulic fluid from saidhigh pressure storage device when operating in said motoring mode andsaid measured pressure is below said predefined threshold.